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Club Car XRT800 2006 Maintenance Service Manual

Gasoline/electric

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2005-2006

MAINTENANCE

SERVICE

MANUAL

XRT800 and XRT810

GASOLINE/ELECTRIC

MANUAL NUMBER 102907719

EDITION CODE 1005B0312A

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Summary of Contents for Club Car XRT800 2006

Page 1 2005-2006 MAINTENANCE SERVICE MANUAL XRT800 and XRT810 GASOLINE/ELECTRIC MANUAL NUMBER 102907719 EDITION CODE 1005B0312A...
Page 3 If the technician does not have such knowledge and skills, attempted service or repairs to the vehicle may render the vehicle unsafe. For this reason, Club Car advises that all repairs and/or service be performed by an authorized Club Car distributor/dealer representative or by a Club Car factory- trained technician.
Page 4 These improvements may affect servicing procedures. Any modification and/or significant change in specifications or procedures will be forwarded to all Club Car dealers and will, when applicable, appear in future editions of this manual.
Page 5: Table Of Contents
CONTENTS SECTION 1 – SAFETY General Warning ..........................SECTION 2 – VEHICLE SPECIFICATIONS SECTION 3 – GENERAL INFORMATION Serial Number Identification ......................Storage – Gasoline Vehicle ......................Preparing the Gasoline Vehicle for Extended Off-Season Storage ..........Returning the Stored Gasoline Vehicle to Service ................ Storage –...
Page 6 Seat Back Support Brackets ......................Seat Back Support Bracket Removal ................... Seat Back Support Bracket Installation ..................Rear Body and Fenders ........................4-10 Rear Body Removal ........................4-10 Forward/Reverse Switch ......................4-11 Rear Fender Removal ........................4-13 Rear Fender Installation ....................... 4-13 Rear Body Installation ........................
Page 7 Steering Wheel ..........................Steering Wheel Removal ......................Steering Wheel Installation ......................Steering Column ..........................Steering Column Removal ......................Steering Column Disassembly ...................... Steering Column Assembly ......................Steering Column Installation ......................Steering Adjustment ......................... Rack and Pinion ..........................Rack and Pinion Removal ......................Rack and Pinion Disassembly ......................
Page 8 Tires ..............................Tire Removal ..........................Tire Repair ............................ Tire Installation ..........................SECTION 9 – REAR SUSPENSION General Information ......................... Shock Absorbers ..........................Shock Absorber Removal and Inspection ..................Shock Absorber Installation ......................Leaf Springs ............................. Leaf Spring Removal ........................Leaf Spring Installation ......................... SECTION 10 –...
Page 9 SECTION 12 – ELECTRICAL COMPONENTS: GASOLINE VEHICLES Starter/Generator ..........................12-1 Voltage Regulator ..........................12-11 Diode ..............................12-12 Key Switch ............................12-14 Solenoid ............................12-15 Fuse ..............................12-16 Lockout Cam Limit Switch ........................ 12-17 Lockout Cam ............................. 12-17 Reverse Warning Buzzer ........................12-18 Reverse Buzzer Limit Switch ......................
Page 10 Engine Installation ..........................13-9 Torque Specifications ........................13-10 Adjustments and Settings ......................13-10 SECTION 14 – FUEL SYSTEM: GASOLINE VEHICLE General Information ......................... 14-1 Carburetor ............................14-1 Main Jet Elevation/Size Chart ...................... 14-2 Changing the Main Jet ......................... 14-2 Engine Control Linkage ........................14-5 General Information ........................
Page 11 Fuel Shut-Off Valve .......................... 14-24 SECTION 15 – EXHAUST SYSTEM: GASOLINE VEHICLES Muffler ............................... 15-1 Muffler Removal ..........................15-1 Muffler Installation ......................... 15-1 SECTION 16 – UNITIZED TRANSAXLE: GASOLINE VEHICLE General Information .......................... 16-1 Lubrication ............................ 16-2 Axle Shaft ............................16-2 Axle Shaft and Oil Seal Removal ....................
Page 12 SECTION 18 – ELECTRICAL SYSTEM AND TESTING: ELECTRIC VEHICLE General Information ......................... 18-1 Wiring Diagram ..........................18-2 Troubleshooting ..........................18-4 Troubleshooting the Vehicle with the Diagnostic Handset ............18-4 Troubleshooting Guide 1 ......................18-5 Troubleshooting Guide 2 ......................18-8 Test Procedures ..........................18-10 Index of Test Procedures ......................
Page 13 Battery Charger ..........................20-4 Charger Shuts Off After 16 Hours ....................20-5 Deep-Discharge ..........................20-5 Early Excessive Discharging ......................20-5 Incoming AC Service ........................20-5 Fleet Rotation ..........................20-5 Numbering Vehicles and Chargers ....................20-5 Battery Troubleshooting Chart ......................20-6 Battery Testing ..........................
Page 14 SECTION 22B – MOTOR (MODEL EJ4-4001) General Information ......................... 22b-1 Motor Identification ........................... 22b-1 External Motor Testing ........................22b-1 Motor ..............................22b-2 Motor Removal ..........................22b-2 Motor Disassembly ........................22b-4 Motor Component Testing and Inspection ..................22b-6 Armature Inspection and Testing ....................22b-6 Motor Frame and Field Windings Inspection ................
Page 15: Section 1 - Safety
SECTION 1 – SAFETY To ensure the safety of those servicing these vehicles, and to protect the vehicles from possible damage resulting from improper service or maintenance, the procedures in this manual must be followed. It is important to note that throughout this manual there are statements labeled DANGER, WARNING, or CAU- TION.
Page 16 SAFETY General Warning ý WARNING • Follow the procedures exactly as stated in this manual, and heed all DANGER, WARNING, and CAUTION statements in this manual as well as those on the vehicle. • Only trained technicians should service or repair the vehicle. Anyone doing even simple repairs or service should have knowledge and experience in electrical and mechanical repair.
Page 17 SAFETY General Warning property damage, personal injury, or death. • For vehicles with cargo beds, remove all cargo before raising the bed or servicing the vehicle. If the vehicle is equipped with a prop rod, ensure that it is securely engaged while bed is raised.
Page 19: Section 2 - Vehicle Specifications
SECTION 2 – VEHICLE SPECIFICATIONS Electric Electric Gasoline Gasoline SPECIFICATIONS XRT 800-E XRT 810-E XRT 800 XRT 810 POWER SOURCE Drive motor: Direct drive, 48 volts DC, shunt-wound, 3.2 hp • Engine: 4-cycle OHV, 286 cc, 9.0 hp rated, single-cylinder, air-cooled, with pressure •...
Page 20 VEHICLE SPECIFICATIONS Electric Electric Gasoline Gasoline SPECIFICATIONS XRT 800-E XRT 810-E XRT 800 XRT 810 800 lb. Vehicle rated capacity: Level surface only (363 kg) Forward speed 17 mph (27 km) Standard seating capacity Liquid Capacities Transaxle 22 oz. (0.67 L) Engine crankcase (without filter) 32 oz.
Page 21: Section 3 - General Information
SECTION 3 – GENERAL INFORMATION ý DANGER • See General Warning, Section 1, Page 1-1. ý WARNING • See General Warning, Section 1, Page 1-1. Important features unique to the different models covered in this manual are highlighted. It is recommended that the owner/operator read and understand this manual and pay special attention to features specific to their vehicle(s).
Page 22: Storage - Gasoline Vehicle
GENERAL INFORMATION Storage – Gasoline Vehicle STORAGE – GASOLINE VEHICLE See General Warning, Section 1, Page 1-1. ý DANGER • Do not drain gasoline when the engine is hot or while it is running. • Be sure to clean up any spilled gasoline before operating the vehicle. •...
Page 23: Returning The Stored Gasoline Vehicle To Service
GENERAL INFORMATION Storage – Gasoline Vehicle CLOSED (OFF) POSITION VENT (SELECTOR IS ALIGNED SHUT-OFF WITH OFF MARKINGS ON THE SIDES OF VALVE) VALVE TO CARBURETOR VIEWED FROM SELECTOR VENT TUBES SIDE OF VALVE Figure 3-2 Fuel Tank, Vent, and Lines Figure 3-3 Fuel Shut-Off Valve –...
Page 24: Storage - Electric Vehicle
GENERAL INFORMATION Storage – Electric Vehicle Returning the Stored Gasoline Vehicle to Service, Continued: PARTIALLY CLOSED POSITION FULL OPEN (ON) POSITION VIEWED FROM SELECTOR VIEWED FROM SELECTOR SIDE OF VALVE SIDE OF VALVE Figure 3-4 Fuel Shut-Off Valve – Open Position Figure 3-5 Incorrect Fuel Shut-off Valve Setting STORAGE –...
Page 25: Returning The Stored Electric Vehicle To Service
GENERAL INFORMATION Storage – Electric Vehicle 4. Adjust tires to recommended tire pressure. See Section 2 – Vehicle Specifications. 5. Perform semiannual periodic lubrication. See Periodic Lubrication Schedules, Section 10, Page 10-4. 6. Thoroughly clean front body, rear body, seats, battery compartment, and underside of vehicle. 7.
Page 27: Section 4 - Body And Trim
SECTION 4 – BODY AND TRIM ý DANGER • See General Warning, Section 1, Page 1-1. ý WARNING • See General Warning, Section 1, Page 1-1. CLEANING THE VEHICLE See General Warning, Section 1, Page 1-1. CAUT ION • Do not use detergents or cleaning solvents that contain ammonia, aromatic solvents, or alkali materials on body panels or seats.
Page 28: Front And Rear Body Repair
BODY AND TRIM Front and Rear Body Repair CAUT ION • To prevent damage to the vehicle when removing difficult stains or heavy soiling, remove the seat bottom from the vehicle first. FRONT AND REAR BODY REPAIR See General Warning, Section 1, Page 1-1. MINOR SCRATCHES AND SURFACE BLEMISHES For minor scratches or blemishes in the body that do not penetrate the finish: 1.
Page 29: Touch-Up Paint Color Chart
TOUCH-UP PAINT COLOR CHART COLOR CLUB CAR P/N Club Car Red CCI P/N 101997203 Club Car Dark Green CCI P/N 101997209 FRONT BODY See General Warning, Section 1, Page 1-1. BUMPER REMOVAL 1. Remove bolts (3) and (5) and lock nuts (4) and pull bumper (1) from vehicle frame (Figure 4-1, Page 4-3).
Page 30: Brush Guard Removal
BODY AND TRIM Front Body BRUSH GUARD REMOVAL 1. Remove bolts (3) and (5) and lock nuts (4) and pull brush guard (2) from vehicle frame (Figure 4-2, Page 4-3). See following WARNING. ý WARNING • Have another person hold brush guard firmly against the frame when removing the last bolt. The brush guard weighs approximately 40 pounds.
Page 31: Dash Installation
BODY AND TRIM Front Body DASH INSTALLATION 1. Pass the steering wheel through the instrument panel hole in the dash. 2. Attach the dash clips along the bottom edge of the dash onto the frame above the floor matt. 3. Install the instrument panel: 3.1.
Page 32: Cargo Bed
BODY AND TRIM Cargo Bed CARGO BED See General Warning, Section 1, Page 1-1. CARGO BED REMOVAL NOTE: This procedure requires two people. 1. Raise bed and remove the rue rings on the end of each clevis pin. 2. Remove hinge clevis pins and remove bed from vehicle. See following CAUTION and WARNING. CAUT ION •...
Page 33 BODY AND TRIM Cargo Bed Figure 4-4 Bed Latch Link Bolt Figure 4-5 Passenger Side Catch Rods and Catch Plate Catch Rod and Catch Plate Removal 1. Remove latch springs. 2. Remove bolts and mechanical lock nuts from latch link and catch plates (Figure 4-5, Page 4-7). 3.
Page 34: Bed Latch Assembly Installation
BODY AND TRIM Seat Back Support Brackets Bed Hinge and Support Bracket Removal 1. Remove steel bushings and urethane bushings from hinge brackets (Figure 4-8, Page 4-8). 2. Remove bolts from hinges and remove hinges from supports. 3. Remove support channel bolts and bushings form hinge support channel (Figure 4-9, Page 4-8). 4.
Page 35: Seat Back Support Bracket Removal
BODY AND TRIM Seat Back Support Brackets Figure 4-10 Bed Latch Plates SEAT BACK SUPPORT BRACKET REMOVAL 1. Remove bolts from seat back and support brackets and remove seat back. 2. Remove seat back support bolts and bed support weldment with bed bumpers from seat back supports (Figure 4-11, Page 4-9).
Page 36: Rear Body And Fenders
BODY AND TRIM Rear Body and Fenders REAR BODY AND FENDERS See General Warning, Section 1, Page 1-1. NOTE: The driver side rear fender can be removed without removing any other component. But the pas- senger side rear fender cannot be removed without either removing the fuel tank, or removing the rear body.
Page 37: Forward/Reverse Switch
BODY AND TRIM Rear Body and Fenders GRAY SENSE LEAD WITH FUSE GRAY WIRE FROM OBC CHARGER RECEPTACLE 10-GAUGE BLACK 10-GAUGE WIRE TO OBC RED WIRE TO BATTERY Figure 4-14 PowerDrive Charger Receptacle 6. Disconnect and remove Forward/Reverse switch. See Forward/Reverse Switch Removal on page 4-11.
Page 38 BODY AND TRIM Rear Body and Fenders Forward/Reverse Switch Removal, Continued: Figure 4-16 Electric Forward/Reverse Switch 2. Remove four screws and nylon lock nuts securing the Forward/Reverse shifter to the rear body. 3. Remove the shifter lever screw, lever and wave washer. 4.
Page 39: Rear Fender Removal
BODY AND TRIM Rear Body and Fenders REAR FENDER REMOVAL NOTE: The driver side rear fender can be removed without removing any other component. But the pas- senger side rear fender cannot be removed without either removing the fuel tank, or removing the rear body.
Page 40: Floor Mat
BODY AND TRIM Floor Mat Rear Body Installation, Continued: 5. Driver side rear fender: NOTE: If only the driver side fender has been removed, use the following procedure for installation 5.1. Install fender in reverse order of removal. 5.2. Tighten side bolts to 25 in-lb (2.8 N·m). 5.3.
Page 41: Section 5 - Accelerator And Brake Pedal Group
SECTION 5 – ACCELERATOR AND BRAKE PEDAL GROUP ý DANGER • See General Warning, Section 1, Page 1-1. ý WARNING • See General Warning, Section 1, Page 1-1. BRAKE PEDAL AND PARK BRAKE See General Warning, Section 1, Page 1-1. BRAKE PEDAL REMOVAL 1.
Page 42: Brake Pedal Installation
ACCELERATOR AND BRAKE PEDAL GROUP Brake Pedal and Park Brake TYPICAL 4 PLACES Service part brake pedal has second TYPICAL weldment. 2 PLACES Figure 5-1 Brake and Park Brake Pedal Assembly BRAKE PEDAL INSTALLATION 1. From the top side of the floorboard, insert the brake pedal assembly through the opening in the floor, and install the brake pedal stop bumper (11) on the brake pedal assembly (Figure 5-1, Page 5-2).
Page 43: Park Brake Removal
ACCELERATOR AND BRAKE PEDAL GROUP Brake Pedal and Park Brake 4. Tighten the nut (2) on the equalizer rod (1) so that brake pedal free-play is 1/4 inch to 1/2 inch (6 mm to 13 mm) (Figure 5-2, Page 5-3). See following NOTE. NOTE: Brake pedal free-play is the distance the brake pedal can be pressed before the brake actuator arm moves.
Page 44: Park Brake Installation
ACCELERATOR AND BRAKE PEDAL GROUP Brake Pedal and Park Brake following NOTE. NOTE: New push nuts (18) and (27) must be used when reassembling the park brake (Figure 5-3, Page 5-4). 3.2. To remove the park brake pedal (1), remove the push nut (27), disconnect the torsion spring (21) (Figure 5-3, Page 5-4) and slide the pedal off of the shaft.
Page 45: Accelerator Pedal - Gasoline Vehicles
ACCELERATOR AND BRAKE PEDAL GROUP Accelerator Pedal – Gasoline Vehicles ACCELERATOR PEDAL – GASOLINE VEHICLES See General Warning, Section 1, Page 1-1. NOTE: This section pertains to gasoline vehicles. For electric vehicles, proceed to Accelerator Pedal – Electric Vehicles on page 5-8. ACCELERATOR PEDAL REMOVAL 1.
Page 46 ACCELERATOR AND BRAKE PEDAL GROUP Accelerator Pedal – Gasoline Vehicles Accelerator Pedal Removal, Continued: FLOORBOARD REMOVED FOR CLARITY Figure 5-5 Accelerator Pedal Assembly – Gasoline Vehicles 12. Inspect the accelerator pivot rod supports (21) for wear or damage and replace as necessary. If the pivot rod supports do not require replacement, loosen, but do not remove the four bolts (22) and lock nuts (15) to make installation of the pivot rod easier.
Page 47: Accelerator Pedal Installation
ACCELERATOR AND BRAKE PEDAL GROUP Accelerator Pedal – Gasoline Vehicles ACCELERATOR PEDAL INSTALLATION 1. If the accelerator pivot rod supports were replaced, position the supports (21) on the vehicle frame and install the four bolts (22), flat washers (8), and lock nuts (15). Finger-tighten nuts at this time (Figure 5-5, Page 5-6).
Page 48: Accelerator Pedal - Electric Vehicles
ACCELERATOR AND BRAKE PEDAL GROUP Accelerator Pedal – Electric Vehicles ACCELERATOR PEDAL – ELECTRIC VEHICLES See General Warning, Section 1, Page 1-1. NOTE: This section pertains to electric vehicles only. For gasoline vehicles go to Accelerator Pedal – Gas- oline Vehicles on page 5-5. ACCELERATOR PEDAL REMOVAL 1.
Page 49 ACCELERATOR AND BRAKE PEDAL GROUP Accelerator Pedal – Electric Vehicles Figure 5-7 Accelerator Pedal – Electric Vehicle 2005-2006 XRT 800, 800-E, 810, 810-E Maintenance and Service Manual Page 5-9...
Page 50: Accelerator Pedal Installation
ACCELERATOR AND BRAKE PEDAL GROUP Accelerator Pedal – Electric Vehicles ACCELERATOR PEDAL INSTALLATION 1. If the accelerator pivot rod supports were replaced, position the supports (21) on the vehicle frame and install the four bolts (22), flat washers (16), and lock nuts (15) (Figure 5-7, Page 5-9). Finger-tighten hardware at this time.
Page 51: Pedal Group Adjustment - Gasoline Vehicle
ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group Adjustment – Gasoline Vehicle PEDAL GROUP ADJUSTMENT – GASOLINE VEHICLE See General Warning, Section 1, Page 1-1. 1. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-2. 2.
Page 52 ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group Adjustment – Gasoline Vehicle Pedal Group Adjustment – Gasoline Vehicle, Continued: 3. Adjust brake pedal free play. See following NOTE. NOTE: Brake pedal free play is the distance the brake pedal can be pressed before the brake actuator arm (at the brake cluster) moves.
Page 53: Bottom View
ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group Adjustment – Gasoline Vehicle CUTAWAY SIDE VIEW 0.060 inch (1.5 mm) BOTTOM VIEW Figure 5-13 Park Brake Ratchet/Pawl Gap Adjustment 4.3. With the park brake unlocked, measure and note the distance from the top of the accelerator pedal to the floorboard, and then lock the park brake (Figure 5-14, Page 5-13).
Page 54 ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group Adjustment – Gasoline Vehicle Pedal Group Adjustment – Gasoline Vehicle, Continued: Figure 5-16 Brake Rod Adjustment Figure 5-17 Accelerator Pedal Height Adjustment 5. Adjust accelerator pedal height. 5.1. Loosen the nut and bolt (Figure 5-17, Page 5-14) securing the accelerator pedal to the pivot plate. 5.2.
Page 55 ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group Adjustment – Gasoline Vehicle 6.2. Loosen the jam nuts (18) and disconnect the accelerator rod (17) at the accelerator pedal. Adjust the length of the rod (Figure 5-5, Page 5-6) to obtain an accelerator cable cam position of 14° as shown (Figure 5-19, Page 5-15).
Page 56: Pedal Group Adjustment - Electric Vehicles
ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group Adjustment – Electric Vehicles PEDAL GROUP ADJUSTMENT – ELECTRIC VEHICLES See General Warning, Section 1, Page 1-1. 1. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-2. 2.
Page 57 ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group Adjustment – Electric Vehicles 3. Adjust brake pedal free play. See following NOTE. NOTE: Brake pedal free play is the distance the brake pedal can be pressed before the brake actuator arm (at the brake cluster) moves. 3.1.
Page 58 ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group Adjustment – Electric Vehicles Pedal Group Adjustment – Electric Vehicles, Continued: CUTAWAY SIDE VIEW 0.060 inch (1.5 mm) BOTTOM VIEW Figure 5-24 Park Brake Ratchet/Pawl Gap Adjustment 4.3. With the park brake unlocked, measure and note the distance from the top of the accelerator pedal to the floorboard, and then lock the park brake (Figure 5-25, Page 5-18).
Page 59 ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group Adjustment – Electric Vehicles Figure 5-27 Brake Rod Adjustment Figure 5-28 Accelerator Pedal Height Adjustment 5. Adjust accelerator pedal height. 5.1. Loosen the nut and bolt (Figure 5-28, Page 5-19) securing the accelerator pedal to the pivot plate. 5.2.
Page 61: Section 6 - Wheel Brake Assemblies
SECTION 6 – WHEEL BRAKE ASSEMBLIES ý DANGER • See General Warning, Section 1, Page 1-1. ý WARNING • See General Warning, Section 1, Page 1-1. • Some aftermarket brake shoes contain asbestos fiber, and asbestos dust is created when these brake mechanisms are handled.
Page 62 WHEEL BRAKE ASSEMBLIES Brake Shoe Removal Brake Shoe Removal, Continued: Figure 6-1 Loosen Equalizer Retaining Nuts Figure 6-2 Remove Axle Retaining Ring 5.2. Insert a 1/2 inch x 5/8 inch cold chisel under the head of each pin and shear them off as illustrated (Figure 6-3, Page 6-2).
Page 63 WHEEL BRAKE ASSEMBLIES Brake Shoe Removal TYPICAL 4 PLACES TYPICAL 4 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES GASOLINE VEHICLE ELECTRIC VEHICLE SEE SECTION 9 – REAR SUSPENSION FOR MOUNTING Figure 6-4 Self-adjusting Wheel Brake Assembly 2005-2006 XRT 800, 800-E, 810, 810-E Maintenance and Service Manual Page 6-3...
Page 64 WHEEL BRAKE ASSEMBLIES Brake Shoe Removal Brake Shoe Removal, Continued: 7. Using needle nose pliers, turn the clip retainer pin (1) 90° to remove the shoe retainer clip (2) (Figure 6-5, Page 6-4). See following CAUTION. ý CAUTION • The brake shoes are under pressure and can release suddenly when brake shoe retainers are removed.
Page 65: Brake Assembly Cleaning
WHEEL BRAKE ASSEMBLIES Brake Assembly Cleaning BRAKE ASSEMBLY CLEANING See General Warning, Section 1, Page 1-1. See also Warning on Page 6-1. 1. Carefully clean the brake backing plate and all of its mechanical components. 2. Remove the rubber boot from backing plate and wipe with a clean damp cloth. 3.
Page 66: Brake Shoe Installation
WHEEL BRAKE ASSEMBLIES Brake Shoe Installation Brake Assembly Cleaning, Continued: 17T STAMPING ON TRAILING SHOE Figure 6-11 Apply Grease To Brake Adjuster Figure 6-12 Install Adjuster Wheel, Trailing Shoe BRAKE SHOE INSTALLATION See General Warning, Section 1, Page 1-1. See also Warning on Page 6-1. 1.
Page 67 WHEEL BRAKE ASSEMBLIES Brake Shoe Installation 4. While maintaining spring attachment on both shoes, position tips of leading shoe in the mounting slots and then push shoe into place. Hold shoe in position and install retaining clip (Figure 6-15, Page 6-7). 5.
Page 68: Brake Adjustment
WHEEL BRAKE ASSEMBLIES Brake Adjustment Brake Shoe Installation, Continued: ý CAUTION • Before installing axle shaft, clean any residual oil from the exposed end of the axle tube and from the oil seal area. 8. Install the brake drum, and make sure that it is properly seated. See following NOTE. NOTE: If drum installation is difficult, the brake shoes may need to be adjusted vertically in the mounting slots.
Page 69: Brake Cluster Installation
WHEEL BRAKE ASSEMBLIES Brake Cable Removal and Installation 5.2. Pull the axle shaft (2) from the axle tube (Figure 6-2, Page 6-2). 6. Remove bow-tie pin (13) and clevis pin (12) from brake cable (Figure 6-4, Page 6-3). 7. Remove four bolts (11) and lock nuts (10) that mount the brake assembly to the transaxle (Figure 6-4, Page 6-3).
Page 70 WHEEL BRAKE ASSEMBLIES Brake Cable Removal and Installation Brake Cable Removal, Continued: Figure 6-18 Loosen Brake Cables 4. Rotate the brake cable upward and pull cable end through hole in top of equalizer (4). 5. Remove E-clip from cable at vehicle frame (5) (Figure 6-18, Page 6-10). Remove cable from frame. 6.
Page 71: Section 7 - Steering And Front Suspension
SECTION 7 – STEERING AND FRONT SUSPENSION ý DANGER • See General Warning, Section 1, Page 1-1. ý WARNING • See General Warning, Section 1, Page 1-1. GENERAL INFORMATION Steering is controlled through a rack and pinion steering assembly that is connected by a steering column to a steering wheel.
Page 72: Steering Wheel Installation
STEERING AND FRONT SUSPENSION Steering Column Steering Wheel Removal, Continued: 5.6. Remove the steering wheel nut (27) and the steering wheel (25) from the steering column (20) (Figure 7-3, Page 7-3). TYPICAL 3 PLACES Figure 7-1 Steering Wheel Puller Figure 7-2 Steering Wheel Puller STEERING WHEEL INSTALLATION NOTE: To minimize corrosion and to make future removal of the steering wheel easier, apply a small amount of oil or anti-seize compound to steering shaft splines and taper before installing the steer-...
Page 73 STEERING AND FRONT SUSPENSION Steering Column TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES Figure 7-3 Steering Column 2005-2006 XRT 800, 800-E, 810, 810-E Maintenance and Service Manual Page 7-3...
Page 74: Steering Column Disassembly
STEERING AND FRONT SUSPENSION Steering Column Steering Column Removal, Continued: 4. Remove the instrument panel. 4.1. Remove the plastic panel screws from the instrument panel. 4.2. Pull dash panel from the dash. 4.3. Disconnect the wires from the electrical components mounted on the dash panel. Do not allow wires to touch.
Page 75: Steering Column Installation
STEERING AND FRONT SUSPENSION Steering Column COLUMN RETAINING TOOL (CCI P/N 1014259) STEP 1 STEP 1 BEARING BEARING PRESS TOOL PRESS TOOL 2-2 1/8 inches (CCI P/N 1014264) (CCI P/N 1014264) (5.1-5.4 cm) STEP 2 WEDGE SEATING INTO THE INNER WEDGE SEATING RACES OF BEARING INTO THE INNER...
Page 76: Steering Adjustment
STEERING AND FRONT SUSPENSION Steering Adjustment Steering Column Installation, Continued: 8. Check the other two bolts on the universal joint (1) to ensure that they are properly tightened to 15 ft-lb (20 N·m) (Figure 7-3, Page 7-3). 9. Reinstall dash pocket and related hardware. 10.
Page 77: Rack And Pinion
STEERING AND FRONT SUSPENSION Rack and Pinion Figure 7-6 Adjust Steering Alignment Figure 7-7 Ball Joint Tool RACK AND PINION See General Warning, Section 1, Page 1-1. RACK AND PINION REMOVAL 1. Remove the front body as instructed in Section 4 – Body and Trim. 2.
Page 78 STEERING AND FRONT SUSPENSION Rack and Pinion Rack and Pinion Disassembly, Continued: 6. Remove the rack screw lock nut (15), rack guide screw (16), rack guide pressure spring (14), and the rack guide (13). 7. Remove the universal joint assembly from the pinion (8) by fully removing the bolt and then sliding off the universal joint.
Page 79: Pinion Gear
STEERING AND FRONT SUSPENSION Rack and Pinion Rack and Pinion Disassembly, Continued: 11. If the ball bearing (9) has been damaged, remove the external snap ring (10) (Figure 7-8, Page 7-8) and press the bearing off (Figure 7-10, Page 7-9). PRESS RAM PINION GEAR BEARING...
Page 80: Rack And Pinion Assembly
STEERING AND FRONT SUSPENSION Rack and Pinion RACK AND PINION ASSEMBLY 1. Install a new tab washer (4) and an inner ball joint (3) (Figure 7-11, Page 7-9). Install the ball joint onto the rack by securing the rack in a vise using wood blocks between the rack and the jaws of the vise to protect the rack from damage.
Page 81 STEERING AND FRONT SUSPENSION Rack and Pinion 12. Install the rack guide (13), pressure spring (14), and screw (16). The screw should be threaded in until a rotational torque of 10 in-lb (1.13 N·m) is achieved (Figure 7-8, Page 7-8). 12.1.
Page 82: Rack And Pinion Installation
STEERING AND FRONT SUSPENSION Tie Rod and Drag Link RACK AND PINION INSTALLATION 1. Position the steering gear box assembly on the shock and gear support and install the bolts (30), wash- ers (31), and nuts (32). Do not tighten the mounting bolts (Figure 7-8, Page 7-8). 2.
Page 83: Front Suspension
STEERING AND FRONT SUSPENSION Front Suspension 3. Thread the drag link rod (28) all the way onto the threaded stud of the inner ball joint assembly (3) (right- hand threads) (Figure 7-8, Page 7-8). 4. Thread the ball joint (23) into the drag link rod (28) (left-hand threads) to full thread depth (Figure 7-8, Page 7-8).
Page 84 STEERING AND FRONT SUSPENSION Front Suspension PROPER CAMBER ADJUSTMENT EQUAL SPACE BETWEEN TIRES AND FRAMING SQUARES IMPROPER CAMBER ADJUSTMENT 7 MM DEEP WELL SOCKET UNEQUAL SPACE BETWEEN TIRES AND FRAMING SQUARES Figure 7-15 Check Camber Figure 7-16 Adjust Camber Toe-in Adjustment 1.
Page 85: Front Suspension Components
STEERING AND FRONT SUSPENSION Front Suspension Components 6. If adjustment is necessary, loosen the jam nut on each tie rod ball joint and rotate the tie rod to increase or decrease toe-in (Figure 7-18, Page 7-14). See following CAUTION. CAUT ION •...
Page 86: Kingpin And Steering Spindle Removal
STEERING AND FRONT SUSPENSION Front Suspension Components KINGPIN AND STEERING SPINDLE REMOVAL 1. Remove the front hub. See Front Wheel Bearings and Hubs on page 7-19. 2. Remove cotter pins (22) and nuts (20), then remove ball joints from the spindles (Figure 7-19, Page 7-17).
Page 87 STEERING AND FRONT SUSPENSION Front Suspension Components TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES Figure 7-19 Upper Front Suspension Assembly 2005-2006 XRT 800, 800-E, 810, 810-E Maintenance and Service Manual Page 7-17...
Page 88 STEERING AND FRONT SUSPENSION Front Suspension Components TYPICAL 4 PLACES TYPICAL 2 PLACES PASSENGER SIDE ONLY TYPICAL DRIVER 2 PLACES SIDE ONLY TYPICAL TYPICAL 2 PLACES 4 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 4 PLACES Figure 7-20 Lower Front Suspension Assembly Page 7-18 2005-2006 XRT 800, 800-E, 810, 810-E Maintenance and Service Manual...
Page 89: Delta A-Plate Installation
STEERING AND FRONT SUSPENSION Front Wheel Bearings and Hubs DELTA A-PLATE INSTALLATION 1. Install the A-Plate in reverse order of removal. Tighten the A-Plate suspension bolts (10 and 24) to 20 ft-lb (27 N·m) (Figure 7-19, Page 7-17). 2. Tighten shock absorber mounting nut (9) to 20 ft-lb (27.1 N·m). 3.
Page 90: Front Hub Installation
STEERING AND FRONT SUSPENSION Front Wheel Bearings and Hubs 5. Inspect the surface of the spindle shaft for surface damage. It should be clean and smooth. If severe pit- ting from rust or corrosion has occurred, replace the spindle assembly. See Kingpin and Steering Spin- dle Removal on page 7-16.
Page 91: Section 8 - Wheels And Tires
SECTION 8 – WHEELS AND TIRES ý DANGER • See General Warning, Section 1, Page 1-1. ý WARNING • See General Warning, Section 1, Page 1-1. GENERAL INFORMATION Maximum tire life and good vehicle handling qualities are directly related to proper wheel and tire care. •...
Page 92: Tire Repair
WHEELS AND TIRES Tires Tire Removal, Continued: 3. If possible, use a tire machine to remove the tire from the rim. 3.1. If a tire machine is not available, loosen both tire beads by applying pressure to the tire side walls and pushing the tire bead away from the rim flange and into the rim well (Figure 8-1, Page 8-2, Detail A).
Page 93: Tire Installation
WHEELS AND TIRES Tires TIRE INSTALLATION ý WARNING • While mounting or inflating tire, keep hands, fingers, etc. from exposed areas between the tire bead and rim. 1. Clean both tire beads to remove dirt or other foreign matter. 2. Where the tire beads seat, clean the wheel rim with a wire brush. Wipe away any debris with a clean cloth.
Page 94 WHEELS AND TIRES Tires Tire Installation, Continued: 7. Quickly remove the air nozzle and install the valve core. 8. Adjust air pressure in tire to recommended pressure. See Section 2 – Vehicle Specifications. 9. Immerse the wheel and tire assembly in water to make sure there are no leaks. Page 8-4 2005-2006 XRT 800, 800-E, 810, 810-E Maintenance and Service Manual...
Page 95: Section 9 - Rear Suspension
SECTION 9 – REAR SUSPENSION ý DANGER • See General Warning, Section 1, Page 1-1. ý WARNING • See General Warning, Section 1, Page 1-1. GENERAL INFORMATION The rear suspension of this vehicle is completely independent. It consists of two leaf springs controlled by two shock absorbers mounted between the springs and the vehicle frame.
Page 96 REAR SUSPENSION Leaf Springs TYPICAL 2 PLACES Figure 9-1 Rear Suspension Assembly and Mounting Page 9-2 2005-2006 XRT 800, 800-E, 810, 810-E Maintenance and Service Manual...
Page 97 REAR SUSPENSION Leaf Springs Leaf Spring Removal, Continued: ý WARNING • Lift only one end of the vehicle at a time. Use a suitable lifting device (chain hoist or hydraulic floor jack) with 1000 lb. (454 kg) minimum lifting capacity. Do not use lifting device to hold vehicle in raised position.
Page 98: Leaf Spring Installation
REAR SUSPENSION Leaf Springs LEAF SPRING INSTALLATION 1. To install the springs, reverse the removal procedure. See following CAUTION. CAUT ION • When positioning the spring on the transaxle, be sure to insert the locating bolt on the spring in the locating hole in the transaxle saddle. 2.
Page 99: Section 10 - Periodic Maintenance
SECTION 10 – PERIODIC MAINTENANCE GENERAL INFORMATION See General Warning on page 1-1. To ensure trouble-free vehicle performance, it is very important to follow an established preventive mainte- nance program (regularly scheduled service). Regular and consistent vehicle maintenance can prevent vehi- cle down-time and expensive repairs that result from neglect.
Page 100: Regular Interval
PERIODIC MAINTENANCE Periodic Service Schedules PERIODIC SERVICE SCHEDULE – ELECTRIC VEHICLES REGULAR INTERVAL SERVICE Daily service by owner Batteries Charge batteries (after each use only). Check electrolyte level. Add water if Weekly service by owner Batteries necessary. See page 20-3. Monthly service by owner Wash battery tops and clean terminals Batteries...
Page 101 PERIODIC MAINTENANCE Periodic Service Schedules PERIODIC SERVICE SCHEDULE – GASOLINE VEHICLES REGULAR INTERVAL SERVICE Monthly service by owner Check engine oil level; change if or trained technician necessary. See Periodic Lubrication Schedules on page 10-4. Check engine cooling air intake; clean if Engine necessary.
Page 102: Periodic Lubrication Schedules
PERIODIC MAINTENANCE Periodic Lubrication Schedules PERIODIC LUBRICATION SCHEDULES PERIODIC LUBRICATION SCHEDULE – ELECTRIC VEHICLES LUBRICATION REGULAR INTERVAL SERVICE RECOMMENDED LUBRICANT POINTS Semiannually by owner or Brake pedal shaft bearings Dry Moly Lube (CCI P/N 1012151) trained technician (or every 50 hours of operation, Brake linkage and pivots Dry Moly Lube (CCI P/N 1012151) whichever comes first)
Page 103: Lubrication Points
PERIODIC MAINTENANCE Periodic Lubrication Schedules PERIODIC LUBRICATION SCHEDULE – GASOLINE VEHICLES LUBRICATION REGULAR INTERVAL SERVICE RECOMMENDED LUBRICANT POINTS Semiannually by owner or Brake pedal shaft bearings Dry Moly Lube (CCI P/N 1012151) trained technician (or every 50 hours of operation, Brake linkage and pivots Dry Moly Lube (CCI P/N 1012151) whichever comes first)
Page 104: Batteries - Electric Vehicles
PERIODIC MAINTENANCE Batteries – Electric Vehicles BATTERIES – ELECTRIC VEHICLES See General Warning, Section 1, Page 1-1. ý DANGER • Battery – Explosive gases! Do not smoke. Keep sparks and flames away from the vehicle and service area. Ventilate when charging or operating vehicle in an enclosed area. Wear a full face shield and rubber gloves when working on or near batteries..
Page 105: Charging Batteries
When inserting the DC plug, align the raised guide on the plug with the guide slot in the receptacle and push straight in slowly. Club Car battery chargers interact with the vehicle onboard computer. The computer records the amount of energy consumed during vehicle use. While the charger is plugged in, the vehicle’s control circuit is locked out, preventing operation of the vehicle as well as the possibility of consequent damage to the charger and the vehicle.
Page 106: Plug And Receptacle
Figure 10-4 Correct Insertion of Charger DC Plug Figure 10-5 Incorrect Insertion of Charger DC Plug Club Car electric vehicles are supplied with a PowerDrive 2 battery charger (CCI P/N 101802204). Use Pow- erDrive 2 chargers with this electric vehicle.
Page 107: Receptacle Fuse Link
WARNING • Do not jump start a dead battery using another battery and jumper cables. The battery in the Club Car gasoline vehicle is a 12-volt, low maintenance battery that requires infrequent watering (Figure 10-7). Any corrosion around the positive (+) or negative (–) terminals should be washed off with a solution of baking soda and water (1 cup (237 mL) per gallon (3.8 L) of water).
Page 108: Engine Oil - Gasoline Vehicles
PERIODIC MAINTENANCE Engine Oil – Gasoline Vehicles Battery – Gasoline Vehicles, Continued: BATTERY CAP LEVEL PLATES INDICATOR ELECTROLYTE LEVEL AT LEAST 1/2 INCH (13 MM) ABOVE PLATES OR TO LEVEL INDICATOR Figure 10-7 Battery – Gasoline Vehicle Figure 10-8 Gasoline Battery Electrolyte Level Be sure battery clamp is properly tightened.
Page 109: Engine Oil And Filter Change
PERIODIC MAINTENANCE Engine Oil – Gasoline Vehicles Full Level Safe Level Level Figure 10-9 Engine Oil Level Check ENGINE OIL AND FILTER CHANGE Engine oil and oil filter should be changed after the first 100 hours of operation. After that, they should be changed every 200 hours of operation or annually, whichever comes first.
Page 110: Drain Plug
This will help seal the filter to the oil mounting bracket. NOTE: Use only Club Car oil filters (CCI P/N 1016467) designed for this engine. 12. Tighten the oil filter by hand until tight. Do not use a band wrench or channel lock pliers to tighten.
Page 111: Drain Pan
PERIODIC MAINTENANCE Engine Oil – Gasoline Vehicles 15. Lower the cargo bed. See WARNING “For vehicles with cargo beds...” in General Warning, Section 1, Page 1-2. 16. With the Forward/Reverse handle in the NEUTRAL position, start and run the engine for a few minutes. Observe both the drain plug and the oil filter from under the vehicle and watch for oil leaks.
Page 112: Fueling Instructions - Gasoline Vehicles
PERIODIC MAINTENANCE Fueling Instructions – Gasoline Vehicles FUELING INSTRUCTIONS – GASOLINE VEHICLES See General Warning, Section 1, Page 1-1. ý DANGER • Turn the key switch to the OFF position before fueling. • Do not pour gasoline into the fuel tank when the engine is hot or while it is running. •...
Page 113: Section 11 - Troubleshooting And Electrical System: Gasoline Vehicle
SECTION 11 – TROUBLESHOOTING AND ELECTRICAL SYSTEM: GASOLINE VEHICLE ý DANGER • See General Warning, Section 1, Page 1-1. ý WARNING • See General Warning, Section 1, Page 1-1. TROUBLESHOOTING GUIDE The following troubleshooting guide will be helpful in identifying operating difficulties should they occur. The guide includes the symptom, probable cause(s) and suggested checks.
Page 114 TROUBLESHOOTING AND ELECTRICAL SYSTEM: GASOLINE VEHICLE Troubleshooting Guide TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES REFER TO Engine turns but fails to start. Section 14 – Fuel System: Gasoline Fuel tank is empty Vehicle Section 14 – Fuel System: Gasoline Fuel line or filters clogged Vehicle Fouled spark plug Section 13 –...
Page 115 TROUBLESHOOTING AND ELECTRICAL SYSTEM: GASOLINE VEHICLE Troubleshooting Guide TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES REFER TO Spark plug fouls repeatedly. Incorrect plug Section 13 – FE290 And FE350 Engines Unsuitable fuel, or incorrect (rich) fuel Section 13 – FE290 And FE350 Engines mixture Spark plug wire is damaged Section 13 –...
Page 116 TROUBLESHOOTING AND ELECTRICAL SYSTEM: GASOLINE VEHICLE Troubleshooting Guide TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES REFER TO Starter/Generator does not charge Section 11 – Troubleshooting and Electrical battery. Diode failed (open condition) System: Gasoline Vehicle, Test Procedure Section 11 – Troubleshooting and Electrical Loose or broken wire in the starter/ System: Gasoline Vehicle, Test Procedure generator circuit...
Page 117: Electrical System
TROUBLESHOOTING AND ELECTRICAL SYSTEM: GASOLINE VEHICLE Electrical System TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES REFER TO Engine won’t stop running. Section 11 – Troubleshooting and Electrical Kill circuit wire is disconnected from the System: Gasoline Vehicle, Test Procedure ignition coil Section 11 – Troubleshooting and Electrical Key switch failure System: Gasoline Vehicle, Test Procedures 4 and 17...
Page 118: Wiring Diagrams
TROUBLESHOOTING AND ELECTRICAL SYSTEM: GASOLINE VEHICLE Wiring Diagrams WIRING DIAGRAMS FUEL TANK SENDING UNIT 16_BLK(W36) HEAD LIGHT CENTER DASH RIGHT PANEL ASM. OIL LIGHT 18_YEL(W41) OIL SENDING UNIT REVERSE 18_RED_WHT_STP(W03) BUZZER FRONT POS (+) NEG (-) FUEL/HOUR METER GUAGE 18_BLU(W11) POWER POINT 18_RED(W33) HEAD LIGHT...
Page 119 TROUBLESHOOTING AND ELECTRICAL SYSTEM: GASOLINE VEHICLE Wiring Diagrams FORWARD LIMIT SWITCH BARE BATTERY 10_NON_INSUL(W37) ENGINE REVERSE LIMIT SWITCH 6_BLK(W38) 18_RED_WHT_STP(W03) 18_ORG(W25) 6_WHT(W08) P/N 1014948 WHITE STARTER GENERATOR 18_BLU(W11) SOLENOID VOLTAGE REGULATOR 18_YEL(W45) 16_BLK(W42) 18_BLK(W40) FUSE BLOCK ELECTRICAL COMPONENT BOX 18_ORG(W25) 18_RED(W04) 14_YEL(W10) 16_ORG(W31)
Page 120: Circuit Testing
TROUBLESHOOTING AND ELECTRICAL SYSTEM: GASOLINE VEHICLE Circuit Testing CIRCUIT TESTING See General Warning, Section 1, Page 1-1. Test the vehicle battery to determine whether or not it is the source of the problem before testing the electrical circuits. A hydrometer, multimeter and 160-ampere load tester will be required. See Test Procedure 1 – Bat- tery on page 11-9.
Page 121 TROUBLESHOOTING AND ELECTRICAL SYSTEM: GASOLINE VEHICLE Test Procedures TEST PROCEDURE 1 – BATTERY See General Warning, Section 1, Page 1-1. ý DANGER • Due to the danger of an exploding battery, wear a full face shield and rubber gloves when working around a battery.
Page 122 TROUBLESHOOTING AND ELECTRICAL SYSTEM: GASOLINE VEHICLE Test Procedures Test Procedure 1 – Battery, Continued: 7. Record the reading. 8. Return the electrolyte to the cell from which it was taken. Replace vent cap. 9. Repeat steps 2 through 8 on all cells. BATTERY PLATES 1.250...
Page 123 TROUBLESHOOTING AND ELECTRICAL SYSTEM: GASOLINE VEHICLE Test Procedures NOTE: A fully charged battery that is in good condition should have a specific gravity of at least 1.225 in all cells, and the difference in the specific gravity of any two cells should be less than 50 points. Open circuit voltage should be at least 12.4 volts.
Page 124 TROUBLESHOOTING AND ELECTRICAL SYSTEM: GASOLINE VEHICLE Test Procedures TEST PROCEDURE 3 – GROUND CABLES See General Warning, Section 1, Page 1-1. 1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in the NEUTRAL posi- tion. Chock the wheels. 2.
Page 125 TROUBLESHOOTING AND ELECTRICAL SYSTEM: GASOLINE VEHICLE Test Procedures Place black (–) probe on frame. WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V Disconnect the 6 gauge black wire from the battery. Place red (+) probe on disconnected end of wire. Figure 11-8 Battery Ground Cable Test TEST PROCEDURE 4 –...
Page 126 TROUBLESHOOTING AND ELECTRICAL SYSTEM: GASOLINE VEHICLE Test Procedures WAVETEK WAVETEK 1000 1000 2000 2000 200k 200k 200nA 200nA 1000 --- 1000 --- FUSED FUSED 750V 750V Reading with key switch Reading with key switch in the ON position in the START position Figure 11-9 Key Switch Test –...
Page 127 TROUBLESHOOTING AND ELECTRICAL SYSTEM: GASOLINE VEHICLE Test Procedures TEST PROCEDURE 6 – SOLENOID See General Warning, Section 1, Page 1-1. 1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in the NEUTRAL posi- tion. Chock the wheels. 2.
Page 128 TROUBLESHOOTING AND ELECTRICAL SYSTEM: GASOLINE VEHICLE Test Procedures Test Procedure 7 – Lockout Cam Limit Switch, Continued: SOLENOID SOLENOID WAVETEK WAVETEK 1000 1000 2000 2000 200k ELECTRICAL 200k COMPONENT 200nA 200nA ELECTRICAL 1000 --- FUSED 1000 --- 750V FUSED 750V COMPONENT BOX FRAME Figure 11-12 Test Solenoid Continuity...
Page 129 TROUBLESHOOTING AND ELECTRICAL SYSTEM: GASOLINE VEHICLE Test Procedures TEST PROCEDURE 8 – STARTER/GENERATOR (STARTER FUNCTION) See General Warning, Section 1, Page 1-1. 1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in the NEUTRAL posi- tion.
Page 130 TROUBLESHOOTING AND ELECTRICAL SYSTEM: GASOLINE VEHICLE Test Procedures Test Procedure 8 – Starter/Generator (Starter Function), Continued: 8. With the wires still disconnected, using a multimeter set to 200 ohms, place the red (+) probe on the DF terminal and the black (–) probe on the F1 terminal. The reading should be between 4.5 and 5.5 ohms. If the reading is incorrect, a possible grounded DF terminal and/or grounded field coil may be the cause.
Page 131 TROUBLESHOOTING AND ELECTRICAL SYSTEM: GASOLINE VEHICLE Test Procedures 7. If the diode tests good, reconnect the diode leads. See Diode Installation, Section 12, Page 12-12. See also following WARNING. ý WARNING • Incorrect wiring could result in severe injury or death. •...
Page 132 TROUBLESHOOTING AND ELECTRICAL SYSTEM: GASOLINE VEHICLE Test Procedures WAVETEK WAVETEK 1000 1000 WHITE WIRE 2000 2000 200k 200k 200nA 200nA 1000 --- FUSED 1000 --- FUSED 750V 750V RED WIRE DIODE DIODE Figure 11-18 Diode Test Figure 11-19 Diode Test – Probes Reversed TEST PROCEDURE 11 –...
Page 133 TROUBLESHOOTING AND ELECTRICAL SYSTEM: GASOLINE VEHICLE Test Procedures 5. Turn the key switch to the OFF position, killing the engine. Using a multimeter set to 20 volts DC, place the red (+) probe on the large post of the solenoid with the red wire from the voltage regulator attached. Place the black (–) probe on the negative (–) battery post (Figure 11-20, Page 11-21).
Page 134 TROUBLESHOOTING AND ELECTRICAL SYSTEM: GASOLINE VEHICLE Test Procedures TEST PROCEDURE 14 – IGNITION SPARK See General Warning, Section 1, Page 1-1. NOTE: Keep the battery connected while performing this test procedure. 1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in the NEUTRAL posi- tion.
Page 135 TROUBLESHOOTING AND ELECTRICAL SYSTEM: GASOLINE VEHICLE Test Procedures TEST PROCEDURE 16 – IGNITION COIL See General Warning, Section 1, Page 1-1. The following test procedures will properly detect a coil that has failed in most cases; however, in rare cases, some ignition coils can fail to operate at normal (warmer) operating temperatures.
Page 136 TROUBLESHOOTING AND ELECTRICAL SYSTEM: GASOLINE VEHICLE Test Procedures WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V Figure 11-25 Secondary Coil Test – In Vehicle Test Figure 11-26 Ignition Coil and Cap Figure 11-27 Spark Plug Cap Removal Page 11-24 2005-2006 XRT 800, 800-E, 810, 810-E Maintenance and Service Manual...
Page 137 TROUBLESHOOTING AND ELECTRICAL SYSTEM: GASOLINE VEHICLE Test Procedures Ignition Coil – In Vehicle Test 1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in the NEUTRAL position. Chock the wheels. 2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-1.
Page 138 TROUBLESHOOTING AND ELECTRICAL SYSTEM: GASOLINE VEHICLE Test Procedures WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V Figure 11-28 Spark Plug Cap Test Ignition Coil – Bench Test 1. Remove the coil from the engine. See Ignition Coil Removal, Section 12, Page 12-23. 2.
Page 139 TROUBLESHOOTING AND ELECTRICAL SYSTEM: GASOLINE VEHICLE Test Procedures WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V Figure 11-29 Secondary Coil Test Without Cap WAVETEK SECONDARY COIL 1000 WAVETEK 1000 2000 200k 2000 200k 200nA 1000 --- FUSED 750V 200nA 1000 --- FUSED 750V...
Page 140 TROUBLESHOOTING AND ELECTRICAL SYSTEM: GASOLINE VEHICLE Test Procedures Test Procedure 16 – Ignition Coil, Continued: WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V Figure 11-32 Secondary Coil Resistance – Bench Test 4. If not previously tested, test the spark plug cap separately from the secondary coil. 4.1.
Page 141 TROUBLESHOOTING AND ELECTRICAL SYSTEM: GASOLINE VEHICLE Test Procedures 3. Remove the instrument panel. See Key Switch Removal, Section 12, Page 12-14. 4. Remove the connector from the key switch. 5. Place the red (+) probe on the (M) terminal and the black (–) probe on the (G) terminal. With the key switch OFF, the reading should be continuity.
Page 142 TROUBLESHOOTING AND ELECTRICAL SYSTEM: GASOLINE VEHICLE Test Procedures TEST PROCEDURE 19 – REVERSE BUZZER LIMIT SWITCH See General Warning, Section 1, Page 1-1. NOTE: Keep the battery connected while performing this test procedure. The reverse buzzer limit switch is located on the Forward/Reverse shifter; red/white and orange wires are connected to it.
Page 143 TROUBLESHOOTING AND ELECTRICAL SYSTEM: GASOLINE VEHICLE Test Procedures TEST PROCEDURE 22 – OIL WARNING LIGHT See General Warning, Section 1, Page 1-1. 1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in the NEUTRAL posi- tion.
Page 144 TROUBLESHOOTING AND ELECTRICAL SYSTEM: GASOLINE VEHICLE Test Procedures TEST PROCEDURE 25 – FUEL LEVEL SENDING UNIT See General Warning, Section 1, Page 1-1. ý WARNING • To avoid the possibility of fire or explosion, make sure the fuel tank cap is securely in place while performing this test procedure.
Page 145 TROUBLESHOOTING AND ELECTRICAL SYSTEM: GASOLINE VEHICLE Test Procedures 18-GAUGE ORANGE WIRE WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V Figure 11-34 Test Fuel Level Sending Unit TEST PROCEDURE 26 – FUEL GAUGE See General Warning, Section 1, Page 1-1. 1.
Page 146 TROUBLESHOOTING AND ELECTRICAL SYSTEM: GASOLINE VEHICLE Test Procedures 18-GAUGE 18-GAUGE ORANGE ORANGE WIRE WIRE WAVETEK WAVETEK 1000 1000 2000 2000 200k 200k 200nA 200nA 1000 --- 1000 --- FUSED FUSED 750V 750V Figure 11-35 Test Fuel Gauge Continuity Figure 11-36 Test Fuel Gauge Voltage TEST PROCEDURE 27 –...
Page 147 TROUBLESHOOTING AND ELECTRICAL SYSTEM: GASOLINE VEHICLE Test Procedures 4. Using a multimeter set on 20 volts DC, place alligator clips on the multimeter probes. Connect the red (+) probe to the light switch terminal with the blue wire connected to it (Figure 11-37, Page 11-35). WAVETEK 1000 2000...
Page 148 TROUBLESHOOTING AND ELECTRICAL SYSTEM: GASOLINE VEHICLE Test Procedures Test Procedure 29 – Headlight Diode, Continued: 5. Loosen the black wire connector (on the end of the long black wire) at the headlight diode assembly just enough to maintain the connection and yet expose part of the metal terminal in the connector. Place black (–) probe on the connector (Figure 11-38, Page 11-36).
Page 149: Black Wire
TROUBLESHOOTING AND ELECTRICAL SYSTEM: GASOLINE VEHICLE Test Procedures 3. Remove the wire harness from the headlight (Figure 11-39, Page 11-37). 4. Using a multimeter set to 20 volts DC, place the black (–) probe of multimeter into the black wire terminal of the wire harness.
Page 151: Section 12 - Electrical Components: Gasoline Vehicles
SECTION 12 – ELECTRICAL COMPONENTS: GASOLINE VEHICLES ý DANGER • See General Warning, Section 1, Page 1-1. ý WARNING • See General Warning, Section 1, Page 1-1. STARTER/GENERATOR See General Warning, Section 1, Page 1-1. Testing the Starter/Generator See Test Procedure 8, Section 11, Page 11-17. Also See Test Procedure 11, Section 11, Page 11-20. Starter/Generator Removal 1.
Page 152 ELECTRICAL COMPONENTS: GASOLINE VEHICLES Starter/Generator A1 TERMINAL TERMINAL TERMINAL TO BATTERY GROUND POST Figure 12-1 Starter/Generator Removal Disassembly of the Starter/Generator to Service the Brushes 1. Remove the two bolts (20) and pull commutator end cover (23) free of starter/generator housing (24) (Figure 12-2, Page 12-2).
Page 153 ELECTRICAL COMPONENTS: GASOLINE VEHICLES Starter/Generator Brush Inspection and Replacement 1. Visually inspect brushes. Replace brushes that are cracked or severely chipped. 2. Check the wear line on the side of the brush. If the end of the brush is within 1/16-inch (1.6 mm) of the wear line, replace all four brushes (Figure 12-4, Page 12-3).
Page 154 ELECTRICAL COMPONENTS: GASOLINE VEHICLES Starter/Generator Starter/Generator Assembly 1. Connect the brush wires to the holders using four lockwashers (26) and four screws (25). Make sure the crossover leads are also connected. Tighten the screws to 31 in-lb (3.5 N·m) (Figure 12-3, Page 12-2). 2.
Page 155 ELECTRICAL COMPONENTS: GASOLINE VEHICLES Starter/Generator Figure 12-7 Armature and Output End Cover Assembly Figure 12-8 Bearing Play Inspection Bearing Removal 1. Place the wedge attachment tool (CCI P/N 1012812) between the bearing and the armature. Make sure the wedge attachment tool is supporting the inner race of the bearing. If a press is not available, secure a bearing puller (CCI P/N 1012811) to the wedge attachment tool and pull the bearing off of the end of the armature shaft.
Page 156 ELECTRICAL COMPONENTS: GASOLINE VEHICLES Starter/Generator WEDGE ATTACHMENT BEARING PRESS RAM USE A 1/2-INCH TOOL PULLER SUPPORT SOCKET OR PIPE TOOL INNER RACE OF BEARING PRESS ON ARMATURE SHAFT USE A WEDGE 1/2-INCH ATTACHMENT SOCKET TOOL OR PIPE NOTE: BEARING IS SECTIONED FOR CLARITY Figure 12-9 Bearing Removal POLE PIECE SCREW...
Page 157 ELECTRICAL COMPONENTS: GASOLINE VEHICLES Starter/Generator Commutator Cleaning and Inspection 1. Clean the carbon dust, dirt and oil from the commutator. Slight roughness of the commutator can be pol- ished away with 400 grit (or finer) sandpaper. See following CAUTION. CAUT ION •...
Page 158: Service Limit
ELECTRICAL COMPONENTS: GASOLINE VEHICLES Starter/Generator ARMATURE WAVETEK 1000 2000 200k COMMUTATOR 200nA 1000 --- FUSED 750V ARMATURE SHAFT Figure 12-12 Armature Ground Test Starter/Generator Rework Any rework must be performed by a qualified technician. Starter/Generator service specifications are listed in the following table.
Page 159 ELECTRICAL COMPONENTS: GASOLINE VEHICLES Starter/Generator CAUT ION • Route the field terminal wires so that they will not contact the armature. 3. Install the four pole pieces into the housing. Use the four screws to secure pole pieces to the inside of the housing to retain the field wires.
Page 160 ELECTRICAL COMPONENTS: GASOLINE VEHICLES Starter/Generator Starter/Generator Installation, Continued: 6. Install the white wire from the solenoid to the F2 terminal on the starter/generator. Install the black wire from the frame to the A2 terminal on the starter/generator. Install a flat washer, lockwasher and nut onto each terminal, and tighten the nut to 48 in-lb (5.4 N·m).
Page 161: Voltage Regulator
ELECTRICAL COMPONENTS: GASOLINE VEHICLES Voltage Regulator VOLTAGE REGULATOR See General Warning, Section 1, Page 1-1. Testing the Voltage Regulator See Test Procedure 12, Section 11, Page 11-20. Voltage Regulator Removal 1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in the NEUTRAL posi- tion.
Page 162: Diode
ELECTRICAL COMPONENTS: GASOLINE VEHICLES Diode DIODE See General Warning, Section 1, Page 1-1. Testing the Diode See Test Procedure 10, Section 11, Page 11-18. Diode Removal 1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in the NEUTRAL posi- tion.
Page 163 ELECTRICAL COMPONENTS: GASOLINE VEHICLES Diode Some wires omitted for clarity. RED FROM VOLTAGE REGULATOR RED FROM DIODE RED FROM WHITE FROM FUSE BLOCK DIODE WHITE FROM STARTER/ RED FROM GENERATOR BATTERY VIEWED FROM INSIDE DRIVER SIDE FRAME OUTER I-BEAM Figure 12-16 Electrical Component Box and Diode Orientation 4.
Page 164: Key Switch
ELECTRICAL COMPONENTS: GASOLINE VEHICLES Key Switch KEY SWITCH See General Warning, Section 1, Page 1-1. Testing the Key Switch See Test Procedure 4, Section 11, Page 11-13. Also see Test Procedure 17 – Key Switch (Engine Kill Circuit) on page 11-28. Key Switch Removal 1.
Page 165: Solenoid
ELECTRICAL COMPONENTS: GASOLINE VEHICLES Solenoid Figure 12-18 Instrument Panel Removal SOLENOID See General Warning, Section 1, Page 1-1. Testing the Solenoid See Test Procedure 6, Section 11, Page 11-15. Solenoid Removal 1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in the NEUTRAL posi- tion.
Page 166: Fuse
ELECTRICAL COMPONENTS: GASOLINE VEHICLES Fuse Solenoid Installation, Continued: 2. Connect all wires as indicated. 2.1. Connect the 6-gauge white wire from the starter/generator, 18-gauge red wire from the voltage reg- ulator, and the 12-gauge white wire from the diode to the large post on the solenoid. See Wiring Diagrams, Section 11, Page 11-6.
Page 167: Lockout Cam Limit Switch
ELECTRICAL COMPONENTS: GASOLINE VEHICLES Lockout Cam Limit Switch LOCKOUT CAM LIMIT SWITCH See General Warning, Section 1, Page 1-1. Testing the Lockout Cam Limit Switch See Test Procedure 7, Section 11, Page 11-15. Lockout Cam Limit Switch Removal 1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in the NEUTRAL posi- tion.
Page 168: Reverse Warning Buzzer
ELECTRICAL COMPONENTS: GASOLINE VEHICLES Reverse Warning Buzzer FORWARD/REVERSE FORWARD/REVERSE ASSEMBLY ASSEMBLY REVERSE BUZZER LOCKOUT LIMIT SWITCH LIMIT SWITCH Figure 12-19 Lockout Cam and Reverse Buzzer Figure 12-20 Lockout Cam Limit Switches Lockout Cam Removal 1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in the NEUTRAL posi- tion.
Page 169: Reverse Buzzer Limit Switch
ELECTRICAL COMPONENTS: GASOLINE VEHICLES Reverse Buzzer Limit Switch 5. Remove the screw (3), nut (4), lockwasher (5) and flat washer (6) securing the buzzer to the vertical frame support. Reverse Warning Buzzer Installation 1. Install the screw (3) through the buzzer (2) bracket tab and frame, secure with hardware, and tighten to 14 in-lb (1.6 N·m) (Figure 12-21, Page 12-19).
Page 170: Oil Warning Light
ELECTRICAL COMPONENTS: GASOLINE VEHICLES Oil Warning Light Reverse Buzzer Limit Switch Removal, Continued: 4. Remove the nuts (2) and washers (6) from the lockout cam limit switch (5) and slide the lockout cam limit switch off of the screws. Do not disconnect the wires. 5.
Page 171: Fuel Gauge/Hour Meter
ELECTRICAL COMPONENTS: GASOLINE VEHICLES Fuel Gauge/Hour Meter Figure 12-22 Fuel Gauge/Hour Meter and Oil Warning Light Assembly FUEL GAUGE/HOUR METER See General Warning, Section 1, Page 1-1. Testing the Fuel Gauge/Hour Meter See Test Procedure 26, Section 11, Page 11-33. Also see Test Procedure 27 – Hour Meter on page 11-34.
Page 172: Fuel Level Sending Unit
ELECTRICAL COMPONENTS: GASOLINE VEHICLES Fuel Level Sending Unit Fuel Gauge/Hour Meter Installation, Continued: 3. Connect the orange wire from the fuel level sending unit to the no. 1 terminal, the blue wire to the no. 2 terminal, the white wire to the No. 4 terminal and the black wire to the No. 3 terminal on the gauge/meter. See Wiring Diagrams, Section 11, Page 11-6.
Page 173: Ignition Coil
ELECTRICAL COMPONENTS: GASOLINE VEHICLES Ignition Coil DAMPER RPM LIMITER BLACK WIRE TO IGNITION COIL FEMALE BULLET TERMINAL BROWN WIRE WHITE/BLACK KILL CIRCUIT WIRE FEMALE BULLET TERMINAL BLACK WIRE Figure 12-23 RPM Limiter Assembly IGNITION COIL See General Warning, Section 1, Page 1-1. The ignition coil is located under the flywheel shroud of the engine.
Page 174 ELECTRICAL COMPONENTS: GASOLINE VEHICLES Ignition Coil Ignition Coil Removal, Continued: 7. Remove the pan head bolts (5) securing the fan shroud (8) to the fan housing (9) (Figure 12-24, Page 12-24). 8. Loosen, but do not remove, three bolts (6) attaching the fan housing as shown. 9.
Page 175 ELECTRICAL COMPONENTS: GASOLINE VEHICLES Ignition Coil 8. Install the gasket (1) on the cap (2). 9. Position the ignition coil (7) onto the cast mounting bosses on the engine crankcase and tighten the two mounting bolts (6) finger-tight. 10. Rotate the flywheel (8) until the magnet is positioned directly under the ignition coil. Use a 0.012 inch (0.304 mm) bronze feeler gauge to set the air gap between the ignition coil and the flywheel magnet.
Page 176: Oil Level Sensor
ELECTRICAL COMPONENTS: GASOLINE VEHICLES Oil Level Sensor Ignition Coil Installation, Continued: 21. Install the starter/generator and belt. See Starter/Generator Installation on page 12-9. 22. Connect the spark plug wire to the spark plug. 23. Connect the battery cables, positive (+) cable first, and tighten the terminals to 12 ft-lb (16.3 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305).
Page 177: Headlights
ELECTRICAL COMPONENTS: GASOLINE VEHICLES Headlights HEADLIGHTS See General Warning, Section 1, Page 1-1. Testing the Headlight Socket See Test Procedure 30, Section 11, Page 11-36. Headlight Bulb Removal 1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in the NEUTRAL posi- tion.
Page 178: Headlight Diode
ELECTRICAL COMPONENTS: GASOLINE VEHICLES Headlight Diode HEADLIGHT DIODE See General Warning, Section 1, Page 1-1. Testing the Headlight Diode See Test Procedure 29, Section 11, Page 11-35. Headlight Diode Removal 1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in the NEUTRAL posi- tion.
Page 179: Battery
ELECTRICAL COMPONENTS: GASOLINE VEHICLES Battery 3. Push the light switch shaft in. Screw the knob onto the end of the shaft until the knob touches the outer nut. Then turn the knob in the opposite direction until the headlight beams on the knob are horizontal to the ground.
Page 180 ELECTRICAL COMPONENTS: GASOLINE VEHICLES Battery Preventive Maintenance, Continued: 2. The battery should be kept clean and dry to prevent self-discharge. Any dirt, grime or acid spillage should be removed. Wash the battery with a bristle brush using water and bicarbonate of soda (1 cup (237 mL) baking soda per 1 gallon (3.8 L) of water).
Page 181 ELECTRICAL COMPONENTS: GASOLINE VEHICLES Battery Battery Removal See General Warning, Section 1, Page 1-1 and DANGER on page 12-29. 1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in the NEUTRAL posi- tion. Chock the wheels. 2.
Page 182: Ground Cables
ELECTRICAL COMPONENTS: GASOLINE VEHICLES Ground Cables Battery Storage See General Warning, Section 1, Page 1-1 and DANGER on page 12-29. 1. Keep the battery clean and free of corrosion. See Preventive Maintenance on page 12-29. 2. The battery cables should be disconnected from the vehicle so it can be connected to the charger. The battery can be left in the vehicle.
Page 183: Section 13 - Fe290 And Fe350 Engines
SECTION 13 – FE290 AND FE350 ENGINES ý DANGER • See General Warning, Section 1, Page 1-1. ý WARNING • See General Warning, Section 1, Page 1-1. GENERAL INFORMATION See General Warning, Section 1, Page 1-1. This gasoline vehicle is powered by a 4-cycle, overhead valve, single cylinder, air-cooled engine. The 4-cycle engine has an oil reservoir (crankcase) similar to automobiles, trucks, aircraft, heavy equipment, machinery and other applications designed for reliable heavy-duty service.
Page 184 FE290 AND FE350 ENGINES General Information Spark Plug Cleaning, Inspection and Repair Examine the plug (Figure 13-1, Page 13-2). The deposits on the plug base and electrode are an indication of the correct heat range and efficiency as well as a guide to the general condition of the engine, fuel and air mix- ture and ignition system.
Page 185: Cylinder Head
FE290 AND FE350 ENGINES Cylinder Head CYLINDER HEAD See General Warning, Section 1, Page 1-1. GENERAL INFORMATION Test cylinder compression using a standard compression tester. Low compression would normally indicate a problem in the cylinder assembly such as defective rings, gaskets, etc. At a cranking speed of 550-600 RPM, the compression should be 156-185 psi.
Page 186 FE290 AND FE350 ENGINES Crankcase Crankcase Cover Removal, Continued: 3. Remove eight bolts (3) and remove the crankcase cover (4). See following NOTE. NOTE: If the crankcase cover sticks, tap lightly with a plastic mallet on alternate sides near the dowel pins (5) (Figure 13-3, Page 13-4).
Page 187: Oil Level Sensor
FE290 AND FE350 ENGINES Crankcase OIL LEVEL SENSOR Testing the Oil Level Sensor See Test Procedure 21, Section 11, Page 11-30. Oil Level Sensor Removal 1. If not already removed, remove crankcase cover. See Crankcase Cover Removal on page 13-3. 2.
Page 188: Ignition Coil And Flywheel
FE290 AND FE350 ENGINES Ignition Coil and Flywheel Crankcase Cover Installation, Continued: 1. Clean the gasket surfaces on the crankcase cover to fit a new gasket during installation and inspect the oil seal for wear and damage. 2. Install crankcase cover. Using HANDS ONLY, seat cover completely against the crankcase. If the cover will not seat, the camshaft is not installed correctly.
Page 189 FE290 AND FE350 ENGINES Ignition Coil and Flywheel Loosen. Remove. Remove. Figure 13-7 Flywheel Housing Figure 13-8 Ignition Coil 3. Hold the flywheel (4), not the fan (7), with a strap wrench (5) and, using a 25 mm socket, remove the fly- wheel nut (and flat washer) by turning it counterclockwise (Figure 13-9, Page 13-7).
Page 190: Flywheel Installation
FE290 AND FE350 ENGINES Flywheel Installation Flywheel Installation See Flywheel Installation on page 13-8. Ignition Coil Inspection and Repair See Test Procedure 16, Section 11, Page 11-23. Ignition Coil Installation 1. Installation is the reverse of removal. 2. While tightening the two bolts (3), use a bronze feeler gauge to adjust the ignition coil air gap to 0.012 inch (0.304 mm) (Figure 13-10, Page 13-7).
Page 191: Engine Installation
FE290 AND FE350 ENGINES Engine Installation ENGINE INSTALLATION See General Warning, Section 1, Page 1-1. 1. Place engine onto engine mounting plate and tighten the mounting hardware (1, 2 and 5) to 13 ft-lb (17.7 N·m). Tighten nuts (6) to 17 ft-lb (23.1 N·m) (Figure 13-4, Page 13-4). 2.
Page 192: Torque Specifications
FE290 AND FE350 ENGINES Engine Installation TORQUE SPECIFICATIONS ITEM SIZE LIMITS Flywheel retaining nut 63 ft-lb (86 N·m) Crankcase cover to block bolts 250 in-lb (28.3 N·m) Starter/Generator 200 in-lb (23 N·m) bracket to block bolts Oil drain plug 20 ft-lb (27.1 N·m) Fan housing screws 90 in-lb (10 N·m) Fan shroud screws...
Page 193: Section 14 - Fuel System: Gasoline Vehicle
SECTION 14 – FUEL SYSTEM: GASOLINE VEHICLE ý DANGER • See General Warning, Section 1, Page 1-1. ý WARNING • See General Warning, Section 1, Page 1-1. GENERAL INFORMATION The engine is equipped with a float bowl type carburetor with fixed jets that require no adjustment. The car- buretor atomizes the fuel, mixes it with air, and feeds the combustible mixture into the cylinder.
Page 194: Main Jet Elevation/Size Chart
FUEL SYSTEM: GASOLINE VEHICLE Carburetor MAIN JET ELEVATION/SIZE CHART FE290 ENGINE ALTITUDE MAIN JET SIZE 0-3000 ft. (0-914.4 m) 3000-5000 ft. (914.4-1524 m) 5000-8000 ft. (1524-2438.4 m) 8000-10,000 ft. (2438.4-3048 m) 10,000 ft. and over (3048 m and over) CHANGING THE MAIN JET 1.
Page 195 FUEL SYSTEM: GASOLINE VEHICLE Carburetor NOTE: Make sure the fuel bowl gasket (9) remains properly seated in the carburetor body when the fuel bowl is removed (Figure 14-2, Page 14-4). During normal operation, the fuel bowl retains the float pivot pin (6). Make sure that the float pivot pin does not fall out of the carburetor body after the fuel bowl is removed.
Page 196 FUEL SYSTEM: GASOLINE VEHICLE Carburetor Changing the Main Jet, Continued: 6. Remove the main jet (8) from the carburetor body and discard it (Figure 14-2, Page 14-4). NOTE: Make sure the fuel nozzle (7) does not fall out of the carburetor body after removal of the main jet. This is best accomplished by positioning the carburetor upside down during main jet removal (Figure 14-2, Page 14-4).
Page 197: Engine Control Linkage
FUEL SYSTEM: GASOLINE VEHICLE Engine Control Linkage NOTE: Inspect the main jet nozzle (7), and pilot jet (4) to ensure they are free from contamination. Replace any part that is clogged with contamination. Replace the float if it is damaged, or if the float valve is damaged or worn.
Page 198: Accelerator Rod
FUEL SYSTEM: GASOLINE VEHICLE Engine Control Linkage ý CAUTION • Improper adjustment can result in poor vehicle performance and/or damage to the engine components. ACCELERATOR ROD ý DANGER • To ensure the vehicle does not run over you while you disconnect or adjust the accelerator push rod, do the following: •...
Page 199 FUEL SYSTEM: GASOLINE VEHICLE Engine Control Linkage 2. Install the ball joint on the ball stud at the accelerator pedal (Figure 14-3, Page 14-6). 3. Access the engine compartment. 4. Remove the electrical box screw and cover. 5. Adjust length of accelerator rod: 5.1.
Page 200: Governor Cable
FUEL SYSTEM: GASOLINE VEHICLE Engine Control Linkage Accelerator Rod Installation and Adjustment, Continued: Pull spring release to install accelerator rod. BOTTOM VIEW Figure 14-5 Accelerator Rod Attachment 8. While pressing the accelerator pedal, the following events should occur in exactly the order shown: APPROXIMATE EVENT PEDAL TRAVEL...
Page 201: Accelerator Cable
FUEL SYSTEM: GASOLINE VEHICLE Engine Control Linkage 5. Disconnect the governor cable (2) from the governor lever arm (15). 6. Remove the governor cable (2) from the governor cable engine bracket (11), and governor cable support bracket (10) (Figure 14-6, Page 14-10). Remove the cable (2) from the vehicle. Governor Cable Installation and Adjustment 1.
Page 202 FUEL SYSTEM: GASOLINE VEHICLE Engine Control Linkage TYPICAL 2 PLACES CARBURETOR THROTTLE Figure 14-6 Governor and Accelerator Cables Page 14-10 2005-2006 XRT 800, 800-E, 810, 810-E Maintenance and Service Manual...
Page 203: Closed Throttle Or Idle Adjustment
FUEL SYSTEM: GASOLINE VEHICLE Engine Control Linkage CLOSED THROTTLE OR IDLE ADJUSTMENT When the accelerator pedal is released, the engine will stop. Therefore, it is not possible to measure or set idling speed under normal vehicle operating conditions. Set throttle valve as follows: 1.
Page 204: Choke And Air Intake System
FUEL SYSTEM: GASOLINE VEHICLE Choke and Air Intake System Engine RPM Adjustment, Continued: 7. Be sure both retaining nuts are locked against the electrical box and then check the RPM again. If the RPM needs to be adjusted, repeat step 6. 8.
Page 205: Intake Duct Removal
FUEL SYSTEM: GASOLINE VEHICLE Choke and Air Intake System INTAKE DUCT REMOVAL 1. Remove the front body. See Front Body Removal, Section 4, Page 4-4. 2. Remove the front left wheel. See Wheel Removal, Section 8, Page 8-1. 3. Remove the steering joint assembly (Figure 14-8, Page 14-13). TYPICAL 3 PLACES Figure 14-8 Compound Steering Joint...
Page 206 FUEL SYSTEM: GASOLINE VEHICLE Choke and Air Intake System REFERENCE CARBURETOR TYPICAL 2 PLACES TYPICAL 3 PLACES TYPICAL 3 PLACES Figure 14-9 Air Intake and Choke Assemblies Page 14-14 2005-2006 XRT 800, 800-E, 810, 810-E Maintenance and Service Manual...
Page 207: Air Filter
• If air box is extremely dirty, remove air box from vehicle and clean thoroughly. • Use only Club Car recommended replacement air filters (603 00 00-04). The use of other air filters could result in engine damage. If the air filter is too thin, the cover will seat before the filter can seal, leaving space for dirt to pass into the engine on all sides of the element.
Page 208 FUEL SYSTEM: GASOLINE VEHICLE Fuel Filters NO. 6 FUEL TANK VENT TUBE TYPICAL 2 PLACES NO. 2 FUEL LINE NO. 1 FUEL LINE NO. 3 FUEL LINE NO. 5 CARBURETOR AIR VENT TUBE NO. 7 NO. 4 IMPULSE FUEL LINE LINE LENGTH FUEL...
Page 209: Fuel Filter Installation
FUEL SYSTEM: GASOLINE VEHICLE Fuel Pump FUEL FILTER INSTALLATION ý CAUTION • Fuel filters are marked with flow direction arrows. Make sure that filters are installed with arrows pointing in the direction of fuel flow from tank to carburetor. 1. Install the primary fuel filter (17) in the fuel line. Use new clamps (16) (Figure 14-10, Page 14-16). 2.
Page 210: Fuel Pump Disassembly
FUEL SYSTEM: GASOLINE VEHICLE Fuel Pump Fuel Pump Removal, Continued: 6. Disconnect the fuel lines (2 and 3) from the pump and plug them to prevent fuel leakage. See following WARNING. ý WARNING • Carefully drain any fuel remaining in the pump into an approved container. Add drained fuel back into fuel tank or dispose of properly.
Page 211: Fuel Pump Assembly
FUEL SYSTEM: GASOLINE VEHICLE Fuel Pump PUMPING FUEL VENT CHAMBER FUEL OUTLET OUTLET VENT FRONT COVER FUEL INLET FUEL INLET VALVE ASSEMBLY DIRECTION OF FUEL FLOW IMPULSE LINE BACK COVER Figure 14-11 Fuel Pump Figure 14-12 Fuel Pump Orientation FUEL PUMP ASSEMBLY 1.
Page 212: Fuel Tank
FUEL SYSTEM: GASOLINE VEHICLE Fuel Tank Fuel Pump Installation, Continued: 4. Install the fuel pump. Tighten nylon lock nuts to 38 in-lb (4.3 N·m). 5. Connect battery cables, positive (+) cable first, and tighten hardware to 12 ft-lb (16 N·m). See Figure 10-1, Section 10, Page 10-1.
Page 213: Fuel Tank Disposal
FUEL SYSTEM: GASOLINE VEHICLE Fuel Tank ý DANGER • Gasoline – Flammable! Explosive! Do not smoke. Keep sparks and flames away from the vehicle and service area. Service only in a well-ventilated area. ý WARNING • Do not attempt to siphon fuel using a hose that does not have a built-in suction device. •...
Page 214: Fuel Tank Storage
FUEL SYSTEM: GASOLINE VEHICLE Fuel Tank FUEL TANK STORAGE 1. Remove the cap from the tank and thoroughly rinse it with water. 2. In a well-ventilated area, flush the fuel tank with water to remove any remaining fuel. 3. In a well-ventilated area, set the tank upside down so that the water can drain out of it. To make sure that the tank dries completely, allow the tank to sit for 24 hours.
Page 215: Fuel Lines
FUEL SYSTEM: GASOLINE VEHICLE Fuel Lines VENT SHUT-OFF VALVE TO CARBURETOR VENT TUBES Figure 14-14 Fuel Tank FUEL LINES See General Warning, Section 1, Page 1-1. The fuel lines must be properly routed, and all hose clamps must be tight. The fuel lines should be kept clean. See following WARNING.
Page 216: Fuel Shut-Off Valve
FUEL SYSTEM: GASOLINE VEHICLE Fuel Shut-Off Valve FUEL SHUT-OFF VALVE See General Warning, Section 1, Page 1-1. The fuel shut-off valve is located on top of the fuel tank (Figure 14-14, Page 14-23). The fuel shut-off valve should always be turned to the closed (OFF) position during vehicle storage, towing or trailering (Figure 14-15, Page 14-24).
Page 217: Section 15 - Exhaust System: Gasoline Vehicles
SECTION 15 – EXHAUST SYSTEM: GASOLINE VEHICLES ý DANGER • See General Warning, Section 1, Page 1-1. ý WARNING • See General Warning, Section 1, Page 1-1. MUFFLER MUFFLER REMOVAL 1. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-1.
Page 218 EXHAUST SYSTEM: GASOLINE VEHICLES Muffler Muffler Installation, Continued: 9. Connect battery cables, positive (+) cable first, and tighten hardware to 12 ft-lb (16 N·m). See Figure 10-1, Section 10, Page 10-1. Coat terminals with Battery Terminal Protector Spray (CCI P/ N 1014305) to minimize corrosion 10.
Page 219: Section 16 - Unitized Transaxle: Gasoline Vehicle
SECTION 16 – UNITIZED TRANSAXLE: GASOLINE VEHICLE ý DANGER • See General Warning, Section 1, Page 1-1. ý WARNING • See General Warning, Section 1, Page 1-1. GENERAL INFORMATION Shifter Lever A shifter lever, connected to a shifter arm, is used to change the gears to one of three shift positions: FOR- WARD (F), NEUTRAL (N), or REVERSE (R) (Figure 16-1, Page 16-1).
Page 220: Lubrication
UNITIZED TRANSAXLE: GASOLINE VEHICLE Axle Shaft Tools Required For This Section Hydraulic floor jack (or chain hoist) Torque wrench, 3/8-in. drive 1/2-in. combination wrench Jack stands (2) (one ton capacity) 3/8-in. socket, 3/8-in. drive 9/16-in. combination wrench Standard slip joint pliers 7/16-in.
Page 221: Axle Bearing
UNITIZED TRANSAXLE: GASOLINE VEHICLE Axle Shaft Figure 16-3 Retaining Ring 8. Position a 16-inch (40 cm) rolling head prybar (Figure 16-4, Page 16-3) under the inside lip of the seal and pull the oil seal out (Figure 16-5, Page 16-3). See following CAUTION. ý...
Page 222: Driver Side
UNITIZED TRANSAXLE: GASOLINE VEHICLE Axle Shaft Axle Bearing Removal, Continued: ý CAUTION • Do not tighten the bearing puller wedge attachment against the axle shaft. This could damage the axle shaft when pressing the bearing and collar off. 2. Press the bearing (71) and collar (73) off together (Figure 16-6, Page 16-4). See also Figure 16-7, Page 16-6.
Page 223: Axle Shaft Installation
UNITIZED TRANSAXLE: GASOLINE VEHICLE Axle Shaft Axle Bearing Installation 1. Ensure that the retaining ring (70) is loosely placed on the axle shaft. See preceding NOTE. 2. Install a new axle bearing (71) on axle (67 or 68). Push bearing onto axle until bearing is flush against axle shoulder (Figure 16-6, Page 16-4).
Page 224: Unitized Transaxle Removal
UNITIZED TRANSAXLE: GASOLINE VEHICLE Unitized Transaxle Removal Axle Shaft Installation, Continued: 4. Install the bearing retaining ring (70) in the axle tube (Figure 16-6, Page 16-4). See also Figure 16-3, Page 16-3. 5. Place a 1/4 to 3/8-inch (6-10 mm) diameter rod against the retaining ring and tap lightly at four to five locations to ensure it is properly seated.
Page 225 UNITIZED TRANSAXLE: GASOLINE VEHICLE Unitized Transaxle Removal VENT TUBE Figure 16-9 Fuel Vent Tube Figure 16-10 Air Intake Hose 4.3. Disconnect impulse line from fuel pump (Figure 16-11, Page 16-7). 4.4. Loosen the hose clamp and then disconnect the fuel line from the carburetor. To prevent spilling fuel, the disconnected end of the line can be plugged with a 1/4-inch bolt (Figure 16-12, Page 16-7).
Page 226 UNITIZED TRANSAXLE: GASOLINE VEHICLE Unitized Transaxle Removal Unitized Transaxle Removal, Continued: ENGINE GROUND RETAINING NUT TOP VIEW RETAINING NUTS Figure 16-13 Throttle Cable Figure 16-14 Engine Ground Wire 4.7. Loosen nuts securing shifter cable to shifter cable mounting bracket. Then disconnect the shifter cable rod end from the shifter arm on the unitized transaxle and remove the cable from the cable mounting bracket (Figure 16-15, Page 16-8).
Page 227 UNITIZED TRANSAXLE: GASOLINE VEHICLE Unitized Transaxle Removal STARTER GENERATOR YELLOW OIL SENDING UNIT JUMPER WIRE WHITE/BLACK WIRE BLACK WIRE Figure 16-17 Oil Level Sensor Jumper Wire Figure 16-18 Ignition Kill Wire 5. Disconnect the brake cables. 5.1. Remove bow tie pins (1), brake cable clevis pins (2), and E-clips (3) (Figure 16-19, Page 16-9). 5.2.
Page 228 UNITIZED TRANSAXLE: GASOLINE VEHICLE Unitized Transaxle Removal Unitized Transaxle Removal, Continued: 6. Remove the lower shock mounting hardware from both rear shocks (Figure 16-20, Page 16-10). 7. Position a floor jack under the vehicle frame crossmember or trailer hitch mount (Figure 16-21, Page 16-10).
Page 229 UNITIZED TRANSAXLE: GASOLINE VEHICLE Unitized Transaxle Removal 10. Continue raising vehicle until frame or trailer hitch is higher than the top of the unitized transmission (enough to allow transaxle and engine to be rolled under and out of vehicle) (Figure 16-24, Page 16-11). 11.
Page 230 UNITIZED TRANSAXLE: GASOLINE VEHICLE Unitized Transaxle Removal Unitized Transaxle Removal, Continued: 15. Place blocks under the engine pan so they will completely support the engine and keep it level to the floor (Figure 16-28, Page 16-12). See following NOTE. NOTE: Place the blocks so they will support the engine when the transaxle is detached and moved away from the engine.
Page 231 UNITIZED TRANSAXLE: GASOLINE VEHICLE Unitized Transaxle Removal 19. Remove screws (1) securing the governor cable bracket to transaxle (Figure 16-32, Page 16-13). 20. Remove screws (1) securing the accelerator cable bracket to transaxle (Figure 16-33, Page 16-13). BRACKET Figure 16-32 Governor Cable Bracket Figure 16-33 Accelerator Cable Bracket 21.
Page 232: Unitized Transaxle Installation
UNITIZED TRANSAXLE: GASOLINE VEHICLE Unitized Transaxle Installation UNITIZED TRANSAXLE INSTALLATION See General Warning, Section 1, Page 1-1. 1. Install the wheels. See Wheel Installation, Section 8, Page 8-1. 2. Install the leaf springs. See Leaf Spring Installation, Section 9, Page 9-4. 3.
Page 233 UNITIZED TRANSAXLE: GASOLINE VEHICLE Unitized Transaxle Installation 12. Remove the blocks from under the engine and roll the powertrain into position under the vehicle. Then lift the front of the powertrain and place the snubber into the snubber bracket in the vehicle frame (Figure 16-39, Page 16-15).
Page 234: Ground Wire
UNITIZED TRANSAXLE: GASOLINE VEHICLE Unitized Transaxle Installation Unitized Transaxle Installation, Continued: 16. Position shocks in the shock mounts and install cushions, mounting washers and nuts (Figure 16-42, Page 16-16). Tighten nuts until cushions expand to be the same diameter as the mounting washers. 17.
Page 235: Top View
UNITIZED TRANSAXLE: GASOLINE VEHICLE Unitized Transaxle Installation 22. Connect the Forward/Reverse shifter and bracket to the transaxle. 22.1. Install the three screws (2) securing the Forward/Reverse shifter cable bracket (1) to the transaxle and tighten them to 135 in-lb (15.3 N·m) (Figure 16-35, Page 16-13). 22.2.
Page 236 UNITIZED TRANSAXLE: GASOLINE VEHICLE Unitized Transaxle Installation Unitized Transaxle Installation, Continued: 27. Connect the impulse line to the fuel pump and secure it with the hose clamp (Figure 16-50, Page 16-18). 28. Connect air intake hose to carburetor and secure hose clamp (Figure 16-51, Page 16-18). IMPULSE LINE Figure 16-50 Impulse Line Figure 16-51 Air Intake Hose...
Page 237: Forward/Reverse Shifter Cable
UNITIZED TRANSAXLE: GASOLINE VEHICLE Forward/Reverse Shifter Cable ý WARNING • If wires are removed or replaced make sure wiring and wiring harness is properly routed and secured to vehicle frame. Failure to properly route and secure wiring could result in vehicle malfunction, property damage or personal injury.
Page 238: Forward/Reverse Shifter Cable Adjustment
UNITIZED TRANSAXLE: GASOLINE VEHICLE Forward/Reverse Shifter Cable Forward/Reverse Shifter Cable Installation, Continued: 4. Install the ball joint socket (10) on the shifter lever ball stud (11) on the transaxle. Figure 16-53 Forward/Reverse Cable Routing 5. Install the ball joint socket (2) on the Forward/Reverse shifter assembly ball stud (3) (Figure 16-54, Page 16-21).
Page 239 UNITIZED TRANSAXLE: GASOLINE VEHICLE Forward/Reverse Shifter Cable Figure 16-54 Forward/Reverse Shifter Cable For major adjustments, the cable retaining nuts (5) must be loosened and adjusted. When the cable is prop- erly adjusted, with the Forward/Reverse handle (9) (Figure 16-54, Page 16-21) in the NEUTRAL position, the shift lever of the transaxle will also be in the NEUTRAL position (Figure 16-55, Page 16-21).
Page 241: Section 17 - Torque Converter: Gasoline Vehicle
SECTION 17 – TORQUE CONVERTER: GASOLINE VEHICLE ý DANGER • See General Warning, Section 1, Page 1-1. ý WARNING • See General Warning, Section 1, Page 1-1. GENERAL INFORMATION The torque converter consists of a drive clutch, a driven clutch, and a drive belt. The drive clutch, which is mounted to the engine, is in the open position when the engine is at idle.
Page 242: Drive Belt
TORQUE CONVERTER: GASOLINE VEHICLE Drive Belt Troubleshooting, Continued: 2. Inspect the driven clutch for dirt and dust buildup on its component parts. Clean the driven clutch with water to remove any dust or dirt, then drive the vehicle and check for proper operation. 3.
Page 243: Drive Belt Installation
TORQUE CONVERTER: GASOLINE VEHICLE Drive Belt 2. Disconnect the spark plug wire from the spark plug. See WARNING “To avoid unintentionally start- ing...” in General Warning, Section 1, Page 1-1. 3. Grasp the belt midway between the drive and driven clutches. Lift upward on the belt to force the sheaves of the DRIVEN clutch apart, then roll the belt off the DRIVEN clutch by rotating the clutch counterclock- wise (Figure 17-2, Page 17-3).
Page 244: Drive Clutch
TORQUE CONVERTER: GASOLINE VEHICLE Drive Clutch DRIVE CLUTCH See General Warning, Section 1, Page 1-1. ý CAUTION • Be very careful when handling the clutches. A clutch that has been dropped will not be properly balanced. If either clutch is dropped, assume that it is damaged and replace it. DRIVE CLUTCH REMOVAL 1.
Page 245: Drive Clutch Cleaning And Inspection
TORQUE CONVERTER: GASOLINE VEHICLE Drive Clutch 3. Place chocks at the front wheels and lift the rear of the vehicle with a chain hoist or floor jack. Place jack stands under the axle tubes to support the vehicle. This will allow the weight of the centerline of the drive clutch to drop below the frame I-beam for access to the bolt securing the drive clutch.
Page 246 TORQUE CONVERTER: GASOLINE VEHICLE Drive Clutch TYPICAL 3 PLACES Figure 17-5 Drive Clutch Assembly Page 17-6 2005-2006 XRT 800, 800-E, 810, 810-E Maintenance and Service Manual...
Page 247: Drive Clutch Disassembly
TORQUE CONVERTER: GASOLINE VEHICLE Drive Clutch DRIVE CLUTCH DISASSEMBLY ý CAUTION • The drive clutch is balanced as an assembly. Before disassembly, make match marks on the drive clutch hub and on the moveable face assembly so they can be reassembled in the same positions (Figure 17-6, Page 17-7).
Page 248 TORQUE CONVERTER: GASOLINE VEHICLE Drive Clutch Remove these 1/4-20 SCREW items from ribs: 10-24 SCREW FLAT WASHER FLAT WASHER WEIGHT DRIVE BUTTON DRIVE BUTTON TAKE UP SPRING RIBS WEIGHT SLOTS IN HUB CASTING Figure 17-8 Drive Button Mounting Figure 17-9 Weight Position 5.
Page 249: Inspection Of Drive Clutch Parts
TORQUE CONVERTER: GASOLINE VEHICLE Drive Clutch 6. Remove the retaining ring (3) from the shaft of the fixed face assembly (7) and slide the moveable face (14) off the shaft (Figure 17-5, Page 17-6). See following NOTE. NOTE: If the moveable face is removed from the hub of the fixed face, the spiral back-up rings (12) must be replaced with new ones (Figure 17-5, Page 17-6).
Page 250: Drive Clutch Assembly
TORQUE CONVERTER: GASOLINE VEHICLE Drive Clutch Inspection of Drive Clutch Parts, Continued: 6. Inspect the pins on the primary weights (2). There should be no measurable wear. Replace them if they are worn, scratched, or damaged. 7. Inspect the drive belt pulley sheaves for excessive wear or damage. If the sheaves are excessively worn or damaged, replace the entire fixed face drive assembly.
Page 251 TORQUE CONVERTER: GASOLINE VEHICLE Drive Clutch 12. Install the 1/4-20 bolts and washers (2) and tighten them to 10 ft-lb (13 N·m) (Figure 17-5, Page 17-6). See following NOTE. NOTE: Make sure there is at least a (minimum) gap of 0.020 inch (0.51 mm) between each end of the mounting pin and the mounting bolt.
Page 252: Drive Clutch Installation
TORQUE CONVERTER: GASOLINE VEHICLE Driven Clutch DRIVE CLUTCH INSTALLATION 1. Place the drive clutch assembly on the crankshaft taper. Position the mounting washer (with the green side facing out) on the bolt (17) and start the bolt into the crankshaft (Figure 17-5, Page 17-6). See fol- lowing NOTE.
Page 253: Driven Clutch Inspection
TORQUE CONVERTER: GASOLINE VEHICLE Driven Clutch DRIVEN CLUTCH CAM PULLER PULLER PLUG Figure 17-16 Remove Retaining Ring Figure 17-17 Driven Clutch Disassembly DRIVEN CLUTCH INSPECTION 1. Inspect the cam (4) for excessive wear. Replace it if necessary (Figure 17-18, Page 17-14). 2.
Page 254 TORQUE CONVERTER: GASOLINE VEHICLE Driven Clutch TYPICAL 3 PLACES Figure 17-18 Driven Clutch Assembly Page 17-14 2005-2006 XRT 800, 800-E, 810, 810-E Maintenance and Service Manual...
Page 255 TORQUE CONVERTER: GASOLINE VEHICLE Driven Clutch Driven Clutch Assembly, Continued: 5. Holding the cam (4) in position for assembly on the shaft, install the other end of the spring (5) into the center spring hole of the cam. Rotate the cam until the keyway is aligned with the key (3) on the fixed face assembly, and then start the cam onto the shaft approximately 1/4 to 3/8 inch (6.3 to 9.5 mm).
Page 256: Driven Clutch Installation
TORQUE CONVERTER: GASOLINE VEHICLE Driven Clutch Driven Clutch Assembly, Continued: 5.2.3. Slide the bolt (1) through the clutch body (5) until the threaded bolt, washers, bearing, and hub guide are against the fixed face hub (Figure 17-20, Page 17-15). 5.2.4. Hold the clutch assembly and cam installation tool together and place the fixed face down on spaced blocks (Figure 17-19, Page 17-15).
Page 257: Section 18 - Electrical System And Testing: Electric Vehicle
SECTION 18 – ELECTRICAL SYSTEM AND TESTING: ELECTRIC VEHICLE ý DANGER • See General Warning, Section 1, Page 1-1. ý WARNING • See General Warning, Section 1, Page 1-1. GENERAL INFORMATION The electric vehicle uses a 48-volt electrical system that is powered by four 12-volt lead-acid batteries and includes an onboard computer.
Page 258: Wiring Diagram
ELECTRICAL SYSTEM AND TESTING: ELECTRIC VEHICLE Wiring Diagram WIRING DIAGRAM 16_ORG(W43) 16_ORG(W43) 14_YEL(W41) 14_YEL(W41) POWER POINT SONIC WELD 18_LT_GREEN(W23) 18_RED(W06) 6_RED(W57) 18_PINK(W21) 18_LT_GREEN(W23) 18_GRAY(W31) REVERSE 18_RED(W26) SONIC WELD BUZZER FRONT 10_BLK(W58) SOLENOID BATTERY INDICATOR WARNING LIGHT 10_BLK(W60) 18_WHT(W22) 18_WHT(W22) RESISTOR 18_PINK(W45) 18_BRN_WHT(W08) 16_BLK_WHT(W42)
Page 259 ELECTRICAL SYSTEM AND TESTING: ELECTRIC VEHICLE Wiring Diagram 16_ORG(W43) 16_ORG(W43) 14_YEL(W41) 14_YEL(W41) EEN(W23) 6_RED(W57) 6_RED(W57) 18_LT_GREEN(W23) TOW SWITCH 18_RED(W26) FUSE & RECEPTACLE SONIC WELD BRACKET ASM 18_WHT(W22) 18_WHT(W22) 18_BRN_WHT(W08) SONIC WELD 16_BLK_WHT(W70) FUSE BLOCK 16_BLK_WHT(W71) FUSE(101894901) (INCLUDED WITH FUSE FUSE BLOCK &...
Page 260: Troubleshooting
ELECTRICAL SYSTEM AND TESTING: ELECTRIC VEHICLE Troubleshooting Wiring Diagram, Continued: • Tow/Run Switch: When the Tow/Run switch is in the RUN position, the vehicle will function normally. When the switch is in the TOW position, power to the OBC and controller is shut off, disabling the vehi- cle operating circuit and zero speed detect, allowing the vehicle to be towed.
Page 261: Troubleshooting Guide 1
ELECTRICAL SYSTEM AND TESTING: ELECTRIC VEHICLE Troubleshooting TROUBLESHOOTING GUIDE 1 The following troubleshooting guide is intended for use with a diagnostic handset. For handset operating instructions, refer to the Diagnostic Handset Owner’s Manual. See following NOTE. NOTE: Before troubleshooting the vehicle, check the diagnostic history from the Special Diagnostics Menu.
Page 262 ELECTRICAL SYSTEM AND TESTING: ELECTRIC VEHICLE Troubleshooting TROUBLESHOOTING GUIDE 1 SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Test Menu – MAIN CONT (solenoid) Disconnect the batteries and allow the does not indicate ON when the speed controller capacitors to discharge. solenoid should be activated. See WARNING “To avoid Speed controller logic malfunction unintentionally starting...”...
Page 263 ELECTRICAL SYSTEM AND TESTING: ELECTRIC VEHICLE Troubleshooting TROUBLESHOOTING GUIDE 1 SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Diagnostic Menu – MAIN COIL FAULT fault code Solenoid coil has failed in an open Replace solenoid. See Solenoid condition Removal, Section 19, Page 19-6. Diagnostic Menu –...
Page 264: Troubleshooting Guide 2
ELECTRICAL SYSTEM AND TESTING: ELECTRIC VEHICLE Troubleshooting TROUBLESHOOTING GUIDE 2 TROUBLESHOOTING GUIDE 2 SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Vehicle does not operate Batteries discharged Charge batteries Check vehicle wiring. See Wiring Improper or poor battery connections Diagram on page 18-2. Battery charger is connected to the Disconnect the battery charger from the vehicle –...
Page 265 ELECTRICAL SYSTEM AND TESTING: ELECTRIC VEHICLE Troubleshooting TROUBLESHOOTING GUIDE 2 SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Vehicle runs slowly Test Procedure 13 – Motor Speed Sensor Speed sensor disconnected or failed on page 18-30 To change the programmed top speed of Incorrect speed setting the vehicle, a diagnostic and programming handset must be used...
Page 266: Test Procedures
ELECTRICAL SYSTEM AND TESTING: ELECTRIC VEHICLE Troubleshooting TEST PROCEDURES Using the following procedures, the entire electrical system can be tested without major disassembly of the vehicle. See following WARNING. ý WARNING • If wires are removed or replaced, make sure wiring and wire harness are properly routed and secured.
Page 267 ELECTRICAL SYSTEM AND TESTING: ELECTRIC VEHICLE Troubleshooting 2. Access the Test menu and select BATT VOLTAGE by using the SCROLL DISPLAY buttons. The handset should indicate at least 48 volts with the batteries fully charged. If not, check for loose battery connec- tions or a battery installed in reverse polarity.
Page 268 ELECTRICAL SYSTEM AND TESTING: ELECTRIC VEHICLE Troubleshooting Batteries / Voltage Check without the Diagnostic Handset, Continued: 4. If reading is zero volts, plug the charger DC cord into the vehicle charger receptacle. If the dash light illu- minates for 10 seconds, the OBC is now powered-up. Unplug the DC cord; the reading at the OBC blue wire should be approximately 48-50 volts.
Page 269 ELECTRICAL SYSTEM AND TESTING: ELECTRIC VEHICLE Troubleshooting Figure 18-4 Diode Test – Probe Position One Figure 18-5 Diode Test – Probe Position Two 4. To remove the diode, carefully clip the two leads where they attach to the solenoid terminals (Figure 18-6, Page 18-13 and Figure 18-7, Page 18-13).
Page 270 ELECTRICAL SYSTEM AND TESTING: ELECTRIC VEHICLE Troubleshooting TEST PROCEDURE 4 – MCOR VOLTAGE See General Warning, Section 1, Page 1-1. The accelerator position, which is proportional to the MCOR voltage, can be displayed with the diagnostic handset. If a handset is not available, proceed to MCOR Voltage Test without the Diagnostic Handset on page 18-14.
Page 271 ELECTRICAL SYSTEM AND TESTING: ELECTRIC VEHICLE Troubleshooting 6. With multimeter set to 20 volts DC, place the black (–) probe on battery no. 4 negative post and the red (+) probe (with insulation-piercing probe) on the no. 18 yellow wire at a point close to three-pin connector at the MCOR.
Page 272 ELECTRICAL SYSTEM AND TESTING: ELECTRIC VEHICLE Troubleshooting TEST PROCEDURE 6 – TOW/RUN SWITCH See General Warning, Section 1, Page 1-1. Tow/Run Switch Test with the Diagnostic Handset 1. With the Tow/Run switch in the RUN position, connect the handset to the vehicle as described in the Diagnostic Handset Owner’s Manual.
Page 273 ELECTRICAL SYSTEM AND TESTING: ELECTRIC VEHICLE Troubleshooting 5. A reading of 32 volts or less will not activate discharge machine. If the voltage of the batteries is below 32 volts, the batteries are deeply discharged or have failed. 6. Recording the battery pack voltage reading while under load provides a more accurate diagnosis of the condition of the batteries.
Page 274 ELECTRICAL SYSTEM AND TESTING: ELECTRIC VEHICLE Troubleshooting Key Switch and MCOR Limit Switch Circuit Test without the Diagnostic Handset 1. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-1. 2. Place chocks at the front wheels and lift the rear of the vehicle with a chain hoist or floor jack. Position jack stands under the frame crossmember between the spring mount and side stringer, just forward of each rear wheel.
Page 275: Test Procedure
ELECTRICAL SYSTEM AND TESTING: ELECTRIC VEHICLE Troubleshooting TEST PROCEDURE 9 – 16-PIN CONNECTOR See General Warning, Section 1, Page 1-1. 1. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-1. 2.
Page 276 ELECTRICAL SYSTEM AND TESTING: ELECTRIC VEHICLE Troubleshooting Test Procedure 9A – Pins 1, 2, and 3 See General Warning, Section 1, Page 1-1. Pins 1, 2, and 3 in the 16-pin connector provide a connection point from the MCOR potentiometer to the speed controller.
Page 277 ELECTRICAL SYSTEM AND TESTING: ELECTRIC VEHICLE Troubleshooting Test Procedure 9B – Pin 5 See General Warning, Section 1, Page 1-1. Pin 5 in the 16-pin connector provides a connection point for the solenoid lockout circuit from the onboard computer to the speed controller. 1.
Page 278: Speed Controller
ELECTRICAL SYSTEM AND TESTING: ELECTRIC VEHICLE Troubleshooting Test Procedure 9B – Pin 5, Continued: 11. While observing the multimeter, disconnect the DC plug from the vehicle charger receptacle. 12. The multimeter should indicate full battery voltage when the charger is not connected to the vehicle. 13.
Page 279 ELECTRICAL SYSTEM AND TESTING: ELECTRIC VEHICLE Troubleshooting 5. Place the Tow/Run switch in the TOW position and connect the battery cables, positive (+) cable first. Tighten battery terminals to 110 in-lb (12.4 N·m). 6. Place the Tow/Run switch in the RUN position, key switch in the ON position, and Forward/Reverse switch in the FORWARD position.
Page 280 ELECTRICAL SYSTEM AND TESTING: ELECTRIC VEHICLE Troubleshooting Key Switch and MCOR Limit Switch Circuit Test without the Diagnostic Handset, Continued: 8. If any other activity is observed, check the following items: • Continuity of the wires in the wire harness •...
Page 281 ELECTRICAL SYSTEM AND TESTING: ELECTRIC VEHICLE Troubleshooting 7. While monitoring the multimeter, place the Forward/Reverse switch in the REVERSE position. The mul- timeter should still indicate zero volts. 8. Place the Forward/Reverse switch in the FORWARD position. The multimeter should indicate full battery voltage (approximately 48 volts).
Page 282 ELECTRICAL SYSTEM AND TESTING: ELECTRIC VEHICLE Troubleshooting Test Procedure 9F – Pin 9, Continued: 1. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-1. 2. Place chocks at the front wheels and lift the rear of the vehicle with a chain hoist or floor jack. Position jack stands under the frame crossmember between the spring mount and side stringer, just forward of each rear wheel.
Page 283 ELECTRICAL SYSTEM AND TESTING: ELECTRIC VEHICLE Troubleshooting Test Procedure 9G – Pin 10 See General Warning, Section 1, Page 1-1. Pin 10 in the 16-pin connector provides a connection point for the key switch to the speed controller. The key switch provides a +48 volt signal to the speed controller through pin 10 when the key switch is in the ON posi- tion.
Page 284 ELECTRICAL SYSTEM AND TESTING: ELECTRIC VEHICLE Troubleshooting Test Procedure 9H – Pin 12 See General Warning, Section 1, Page 1-1. Pin 12 in the 16-pin connector provides a connection point for the solenoid coil to the speed controller. The speed controller activates the solenoid coil by providing a ground to the solenoid coil at the appropriate time. 1.
Page 285 ELECTRICAL SYSTEM AND TESTING: ELECTRIC VEHICLE Troubleshooting TEST PROCEDURE 10 – ONBOARD COMPUTER SILICON-CONTROLLED RECTIFIER (SCR) CIRCUIT See General Warning, Section 1, Page 1-1. The silicon controlled rectifier (SCR), located inside the onboard computer, acts as a switch on the negative side of the circuit.
Page 286 ELECTRICAL SYSTEM AND TESTING: ELECTRIC VEHICLE Troubleshooting TEST PROCEDURE 13 – MOTOR SPEED SENSOR See General Warning, Section 1, Page 1-1. Motor Speed Sensor Test with the Diagnostic Handset ý CAUTION • Perform the following procedure only on a level surface. To avoid injury or property damage, ensure that the path of the vehicle is clear before pushing vehicle.
Page 287 ELECTRICAL SYSTEM AND TESTING: ELECTRIC VEHICLE Troubleshooting 6. Reconnect the three-pin connector at the motor speed sensor. Using a multimeter set to 20 volts DC, place the black (–) probe on the battery no. 4 negative post and place the red (+) probe (with insulation- piercing probe) on the green wire between the three-pin connector and the motor speed sensor.
Page 288 ELECTRICAL SYSTEM AND TESTING: ELECTRIC VEHICLE Troubleshooting TEST PROCEDURE 15 – FORWARD/REVERSE ROCKER SWITCH See General Warning, Section 1, Page 1-1. Forward/Reverse Rocker Switch Test with the Diagnostic Handset 1. Turn the key switch to the OFF position and place the Forward/Reverse switch in the NEUTRAL position. 2.
Page 289 ELECTRICAL SYSTEM AND TESTING: ELECTRIC VEHICLE Troubleshooting TEST PROCEDURE 16 – REVERSE BUZZER See General Warning, Section 1, Page 1-1. 1. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-1. 2.
Page 290 ELECTRICAL SYSTEM AND TESTING: ELECTRIC VEHICLE Troubleshooting TEST PROCEDURE 17 – REBOOTING THE ONBOARD COMPUTER See General Warning, Section 1, Page 1-1. It is possible the Onboard Computer (OBC) can become “locked up,” causing the OBC solenoid lockout circuit to malfunction. If this condition is suspected, restart the computer as follows: 1.
Page 291: Communication Display Module (Cdm)
ELECTRICAL SYSTEM AND TESTING: ELECTRIC VEHICLE Troubleshooting COMMUNICATION DISPLAY MODULE (CDM) LOW BATTERY INDICATOR DISPLAY WINDOW COMMUNICATION DISPLAY MODULE BATTERY DISPLAY FUNCTIONS: PRESS AND HOLD BUTTON TO SHOW FUNCTION NUMBER. RELEASE BUTTON TO SHOW FUNCTION VALUE. FUNCTION Func1 - Battery voltage. Func2 - Energy units removed since last charge cycle.
Page 292: Using The Cdm To Retrieve Data From The Onboard Computer
ELECTRICAL SYSTEM AND TESTING: ELECTRIC VEHICLE Troubleshooting 2 – Indicates a back-up charge program was employed by the OBC to complete the charge cycle. A DVDT charge may be displayed the first few times a new set of batteries is charged, and the first time a set of batteries is charged after the batteries have been disconnected and reconnected.
Page 293: Cdm Troubleshooting Guide
ELECTRICAL SYSTEM AND TESTING: ELECTRIC VEHICLE Troubleshooting CDM TROUBLESHOOTING GUIDE Use the following chart as a starting point for troubleshooting problems with communication between the CDM and onboard computer. Contact your nearest distributor/dealer representative for more comprehensive information. OBC Will Not Communicate With The CDM Failed Dash Light CDM battery...
Page 295: Section 19 - Electrical Components: Electric Vehicle
SECTION 19 – ELECTRICAL COMPONENTS: ELECTRIC VEHICLE ý DANGER • See General Warning, Section 1, Page 1-1. ý WARNING • See General Warning, Section 1, Page 1-1. KEY SWITCH See General Warning, Section 1, Page 1-1. Testing the Key Switch See Test Procedure 8, Section 18, Page 18-17.
Page 296: Forward/Reverse Rocker Switch
ELECTRICAL COMPONENTS: ELECTRIC VEHICLE Forward/Reverse Rocker Switch Figure 19-2 Key Switch Removal Key Switch Installation 1. Install the key switch in the dash in reverse order of removal. Tighten the key switch nut firmly. Reconnect the wire connector to the key switch. 2.
Page 297: Tow/Run Switch
ELECTRICAL COMPONENTS: ELECTRIC VEHICLE Tow/Run Switch 5. Place the Tow/Run switch in the RUN position. 6. Inspect the vehicle for proper operation: • Make sure that the vehicle operates in the forward direction when the Forward/Reverse switch is in the FORWARD position.
Page 298: Motor Controller Output Regulator (Mcor)
ELECTRICAL COMPONENTS: ELECTRIC VEHICLE Motor Controller Output Regulator (MCOR) Tow/Run Switch Installation 1. Installation is reverse of removal. Make sure groove on switch is aligned with tang on bracket. Tighten Tow/Run switch boot/hex nut (6) to 16 in-lb (1.8 N·m) (Figure 19-3, Page 19-3). 2.
Page 299: Reverse Buzzer
ELECTRICAL COMPONENTS: ELECTRIC VEHICLE Reverse Buzzer MCOR Removal 1. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-1. 2. Place chocks at rear wheels and lift the front of the vehicle with a chain hoist or floor jack. Place jack stands under the round tube crossmember of the frame to support vehicle.
Page 300: Solenoid
ELECTRICAL COMPONENTS: ELECTRIC VEHICLE Solenoid SOLENOID See General Warning, Section 1, Page 1-1. The solenoid is located on the driver side of the electrical component mounting plate. Testing the Solenoid See Section 18, Test Procedure 3, Page 18-12 and Test Procedure 14, Page 18-31. Solenoid Removal 1.
Page 301: Onboard Computer (Obc)
ELECTRICAL COMPONENTS: ELECTRIC VEHICLE Onboard Computer (OBC) ONBOARD COMPUTER (OBC) See General Warning, Section 1, Page 1-1. Testing the Onboard Computer See Section 18, Test Procedure 2, Page 18-11, Test Procedure 10, Page 18-29, and Test Procedure 11, Page 18-29. Onboard Computer Removal 1.
Page 302 ELECTRICAL COMPONENTS: ELECTRIC VEHICLE Onboard Computer (OBC) Onboard Computer Installation, Continued: 3. Install the OBC onto the component mounting plate by aligning the two holes on the OBC face plate with two holes on component mounting plate. Slide OBC towards inside of vehicle and align heads of self-tap- ping screws (17) with smaller part of two holes in OBC face plate (Figure 19-6, Page 19-7).
Page 303: Solid State Speed Controller
ELECTRICAL COMPONENTS: ELECTRIC VEHICLE Solid State Speed Controller SOLID STATE SPEED CONTROLLER See General Warning, Section 1, Page 1-1. Testing the Solid State Speed Controller See Test Procedure 5, Section 18, Page 18-15. Speed Controller Removal 1. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-1.
Page 304: Charger Receptacle
ELECTRICAL COMPONENTS: ELECTRIC VEHICLE Charger Receptacle Speed Controller Installation 1. Install the three self-tapping screws (17) that hold the controller (6) to the component mounting plate and tighten to 60 in-lb (6.8 N·m) (Figure 19-8, Page 19-9). 2. Using the wiring diagram, install the multi-pin connectors and all wires as illustrated. See Wiring Dia- gram, Section 18, Page 18-2.
Page 305 ELECTRICAL COMPONENTS: ELECTRIC VEHICLE Charger Receptacle Charger Receptacle Removal 1. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-1. 2. Remove the 10-gauge red wire (4) from the positive post of battery no. 1 (Figure 19-9, Page 19-11). 3.
Page 306: Receptacle Fuse Link
ELECTRICAL COMPONENTS: ELECTRIC VEHICLE Battery Warning Light RECEPTACLE FUSE LINK The fuse link on the 48-volt electric vehicle should not blow under normal operating conditions; however, if the fuse link has blown, the vehicle will not charge and the fuse must be replaced. The fuse link (6) is mounted on top of the charger receptacle in the battery compartment (Figure 19-9, Page 19-11).
Page 307: Pin 9 Diode
ELECTRICAL COMPONENTS: ELECTRIC VEHICLE Battery Warning Light PIN 9 DIODE See General Warning, Section 1, Page 1-1. Testing the Pin 9 Diode See Test Procedure 9F, Section 18, Page 18-25. If the pin 9 diode has failed open, it should be removed from the harness. Instead of replacing the diode with a new one, we recommend installing a Main Dropout Harness (CCI P/N 102355201) between the Tow/Run switch and the wire harness.
Page 309: Section 20 - Batteries: Electric Vehicles
SECTION 20 – BATTERIES: ELECTRIC VEHICLES ý DANGER • See General Warning, Section 1, Page 1-1. ý WARNING • See General Warning, Section 1, Page 1-1. ý DANGER • Battery – Explosive gases! Do not smoke. Keep sparks and flames away from the vehicle and service area.
Page 310: Battery Care
BATTERIES: ELECTRIC VEHICLES Battery Care Battery Replacement, Continued: 1. Before removing batteries, note the orientation of the batteries and the connecting wires. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warn- ing, Section 1, Page 1-1. Remove remaining wires and batteries. See Wiring Diagram, Section 18, Page 18-2.
Page 311: Self-Discharge
BATTERIES: ELECTRIC VEHICLES Battery Care 2. Batteries should be clean and free of corrosion. Wash tops and terminals of batteries with a solution of baking soda and water (1 cup (237 mL) baking soda per 1 gallon (3.8 L) of water). Rinse solution off bat- teries.
Page 312: Mineral Content
BATTERIES: ELECTRIC VEHICLES Battery Charger Electrolyte Level, Continued: The electrolyte level should be checked weekly to be sure electrolyte is at its proper level (Figure 20-2, Page 20-3). Never allow the electrolyte level to fall below the tops of the plates because this will cause the exposed part of the plate to become permanently inactive.
Page 313: Charger Shuts Off After 16 Hours
BATTERIES: ELECTRIC VEHICLES Battery Charger CHARGER SHUTS OFF AFTER 16 HOURS This may be due to 1) new batteries, 2) hard use, or 3) cold temperatures. A catch-up charge may be neces- sary when these conditions are present. On those days when all or some of the vehicles do not get used, check the batteries for state of charge.
Page 314: Battery Troubleshooting Chart
BATTERIES: ELECTRIC VEHICLES Battery Troubleshooting Chart BATTERY TROUBLESHOOTING CHART Vehicle not operating to expectation. Fully Charge Batteries. Battery Charger Test Reading of 6 amps or more. Reading below 6 amps and on-charge voltage above 56 volts. Check electrical system and charger for problems.
Page 315: Battery Testing
BATTERIES: ELECTRIC VEHICLES Battery Testing BATTERY TESTING See General Warning, Section 1, Page 1-1. Four tests have been developed to help diagnose problems with batteries that have not performed as expected. Because each test becomes progressively more detailed and time-consuming, begin with the first test and follow through with the other tests until the problem has been identified as outlined in the Battery Troubleshooting Chart (Figure 20-3, Page 20-6).
Page 316 BATTERIES: ELECTRIC VEHICLES Battery Testing Performing the Hydrometer Test, Continued: 5. Hold the hydrometer vertically, ensuring that the float is not touching the sides of the barrel. Hold the hydrometer at eye level and read the scale at the level of electrolyte (Figure 20-4, Page 20-8). 6.
Page 317: Discharge Test
BATTERIES: ELECTRIC VEHICLES Battery Testing CORRECTED SPECIFIC GRAVITY VEHICLE BATTERY ELECTROLYTE CORRECTION REQUIRED TEMPERATURE FACTOR ACTION CELL 1 CELL 2 CELL 3 CELL 4 CELL 5 CELL 6 1.275 – 1.280 – 1.280 – 1.275 – 1.280 – 1.280 – 20 °F Sound Battery –...
Page 318 BATTERIES: ELECTRIC VEHICLES Battery Testing Performing the Discharge Test, Continued: 3. Check and record the electrolyte temperature of the battery packs. Check cell no. 2 (second cell from positive post) in each battery. 4. Reset discharge machine and turn the tester ON. 5.
Page 319: Battery Troubleshooting Examples
BATTERIES: ELECTRIC VEHICLES Battery Testing BATTERY TROUBLESHOOTING EXAMPLES The following information represents a few examples of troubleshooting battery problems. Example 1 Vehicle no. 68 was suspected of having a bad battery due to its performance. As a result, the battery charger test was performed.
Page 320: Battery Storage
BATTERIES: ELECTRIC VEHICLES Battery Storage BATTERY STORAGE See General Warning, Section 1, Page 1-1. When storing batteries during the off-season or when maintaining a replacement stock, follow these guidelines: 1. Keep the batteries clean and free of corrosion. See Battery Care on page 20-2. 2.
Page 321: Section 21 - Battery Charger: Electric Vehicle
SECTION 21 – BATTERY CHARGER: ELECTRIC VEHICLE Refer to the battery charger maintenance and service manual (CCI P/N 102680414). 2005-2006 XRT 800, 800-E, 810, 810-E Maintenance and Service Manual Page 21-1...
Page 323: Section 22A - Motor (Model 5Bc59Jbs6365)
SECTION 22A – MOTOR (MODEL 5BC59JBS6365) ý DANGER • See General Warning, Section 1, Page 1-1. ý WARNING • See General Warning, Section 1, Page 1-1. GENERAL INFORMATION The electric vehicle is equipped with a 48-volt DC, shunt-wound, reversible traction motor. The shunt-wound motor is designed for use on electric vehicles only.
Page 324: Motor
MOTOR (MODEL 5BC59JBS6365) Motor TEST PROCEDURE 2 – ARMATURE CIRCUIT OPEN See General Warning, Section 1, Page 1-1. 1. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-1. 2. Disconnect wires from the A1 and A2 terminals on the motor using two wrenches to prevent posts from turning.
Page 325 MOTOR (MODEL 5BC59JBS6365) Motor Figure 22a-1 Lift Vehicle with Floor Jack Figure 22a-2 Vehicle Supported on Jack Stands 5. Remove both rear wheels. 6. Remove the nut, cup washer, and bushing from the bottom side of the shock absorber. Compress the shock absorber (pushing upwards) to move it out of the way (Figure 22a-3, Page 22a-3).
Page 326 MOTOR (MODEL 5BC59JBS6365) Motor Motor Disassembly 1. Before beginning disassembly, place match marks on the motor end shield and stator shell, then place the motor in a vice with wooden blocks as shown (Figure 22a-4, Page 22a-4). 2. Remove the four bolts (8) securing the end shield (10) to the stator shell (2). 3.
Page 327: Motor Component Testing And Inspection
MOTOR (MODEL 5BC59JBS6365) Motor MOTOR COMPONENT TESTING AND INSPECTION See General Warning, Section 1, Page 1-1. ARMATURE Visual Inspection Disassemble the motor and carefully inspect the armature for the following characteristics: • Burned, charred or cracked insulation • Improperly cured varnish •...
Page 328: Field Windings Inspection
MOTOR (MODEL 5BC59JBS6365) Motor ARMATURE CORE COMMUTATOR Figure 22a-6 Armature Test FIELD WINDINGS INSPECTION Burned or scorched insulation on the field windings indicates the motor has overheated due to overloads or grounded or shorted coil windings. If the insulation on the field windings is scorched, replace the motor or the stator shell assembly.
Page 329: Bearing Inspection
MOTOR (MODEL 5BC59JBS6365) Motor BEARING INSPECTION 1. Use a clean cloth to wipe the carbon dust off of the bearing. Inspect the bearing by spinning it by hand and checking for both axial (A) and radial (B) play (Figure 22a-8, Page 22a-7). 2.
Page 330 MOTOR (MODEL 5BC59JBS6365) Motor TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 4 PLACES TYPICAL 3 PLACES Figure 22a-9 Motor – Model 5BC59JBS6365 Page 22a-8 2005-2006 XRT 800, 800-E, 810, 810-E Maintenance and Service Manual...
Page 331: Speed Sensor Magnet Inspection
MOTOR (MODEL 5BC59JBS6365) Reconditioning the Motor SPEED SENSOR MAGNET INSPECTION Inspect the speed sensor magnet (18) for rust, wear, and cracks (Figure 22a-9, Page 22a-8). Replace the magnet if necessary. SPEED SENSOR MAGNET REMOVAL 1. To remove the speed sensor magnet (18), remove the motor bearing (Figure 22a-9, Page 22a-8). See Bearing Removal on page 22a-7.
Page 332: Motor Assembly
MOTOR (MODEL 5BC59JBS6365) Reconditioning the Motor MOTOR ASSEMBLY See General Warning, Section 1, Page 1-1. 1. If the bearing has been removed, replace the bearing. See Bearing Installation on page 22a-7. 2. Install the brushes. See following NOTE. NOTE: When installing new brushes, remove and replace brushes one at a time. This method ensures the terminals and brushes will be properly positioned in the rigging.
Page 333 MOTOR (MODEL 5BC59JBS6365) Reconditioning the Motor 2.3. Slide the armature, bearing end first, into the stator shell. Make sure the brushes are held back while positioning the armature for proper commutator/brush contact. Release the brushes and place the springs outside the brushes so the brushes are being held against the commutator. See following CAUTION.
Page 334: Motor Installation
MOTOR (MODEL 5BC59JBS6365) Motor Installation MOTOR INSTALLATION See General Warning, Section 1, Page 1-1. 1. Clean the transaxle input shaft. ® 1.1. Spray the input shaft thoroughly with CRC Brakleen™ or equivalent brake cleaner degreaser. 1.2. Wipe input shaft with a clean cloth. 1.3.
Page 335: Shaft End
MOTOR (MODEL 5BC59JBS6365) Motor Installation 4. Install motor on transaxle. 4.1. Slide the motor coupling onto the transaxle input shaft. See following NOTE. NOTE: The coupling will push any excess grease on the input shaft along the shaft toward the transaxle. When the motor is pushed onto the input shaft, the motor adapter ring (1) will not bottom out against the transaxle housing (Figure 22a-9, Page 22a-8).
Page 336 MOTOR (MODEL 5BC59JBS6365) Motor Installation Motor Installation, Continued: 6. Insert the mounting bolts through the spring shackles and the bushings in the leaf spring eyes and install locknuts. Tighten the bolts to 23 ft-lb (31 N·m). See Leaf Spring Installation, Section 9, Page 9-4. 7.
Page 337: Motor Speed Sensor
MOTOR (MODEL 5BC59JBS6365) Motor Speed Sensor MOTOR SPEED SENSOR See General Warning, Section 1, Page 1-1. Testing the Motor Speed Sensor See Test Procedure 13, Section 18, Page 18-30. Motor Speed Sensor Removal 1. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-1.
Page 339: Section 22B - Motor (Model Ej4-4001)
SECTION 22B – MOTOR (MODEL EJ4-4001) ý DANGER • See General Warning, Section 1, Page 1-1. ý WARNING • See General Warning, Section 1, Page 1-1. GENERAL INFORMATION The electric vehicle is equipped with a 48-volt DC, shunt-wound, reversible traction motor. The shunt-wound motor is designed for use on electric vehicles only.
Page 340: Motor
MOTOR (MODEL EJ4-4001) Motor TEST PROCEDURE 2 – ARMATURE CIRCUIT OPEN See General Warning, Section 1, Page 1-1. 1. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-1. 2. Disconnect wires from the A1 and A2 terminals on the motor using two wrenches to prevent posts from turning.
Page 341 MOTOR (MODEL EJ4-4001) Motor Figure 22b-1 Lift Vehicle with Floor Jack Figure 22b-2 Vehicle Supported on Jack Stands 5. Remove both rear wheels. 6. Remove the nut, cup washer, and bushing from the bottom side of the shock absorber. Compress the shock absorber (pushing upwards) to move it out of the way (Figure 22b-3, Page 22b-3).
Page 342: Motor Disassembly
MOTOR (MODEL EJ4-4001) Motor Figure 22b-4 Speed Sensor Magnet Figure 22b-5 End Cap MOTOR DISASSEMBLY 1. Before beginning disassembly, place match marks on the motor end cap and motor frame. 2. Remove speed sensor and magnet. 2.1. Remove the two screws (25) that secure the speed sensor (10) to the end cap (11) (Figure 22b-15, Page 22b-10).
Page 343 MOTOR (MODEL EJ4-4001) Motor CAUT ION • Ensure that there is sufficient thread engagement of the end cap bolts before proceeding. Performing the procedure without having adequate thread engagement could damage the motor frame, end cap, or end cap bolts. 5.2.
Page 344: Motor Component Testing And Inspection
MOTOR (MODEL EJ4-4001) Motor Component Testing and Inspection Figure 22b-8 Armature Removal Figure 22b-9 A1 and A2 Terminals Figure 22b-10 Brush Rigging Figure 22b-11 Bearing Retaining Ring MOTOR COMPONENT TESTING AND INSPECTION See General Warning, Section 1, Page 1-1. ARMATURE INSPECTION AND TESTING 1.
Page 345 MOTOR (MODEL EJ4-4001) Motor Component Testing and Inspection • Damaged armature core laminations • Worn, burned or glazed commutators • Dirty or oily commutators • Raised commutator bars • Worn armature bearing or shaft A dirty or oily commutator should be cleaned and wiped dry. Abnormalities identified during the inspection can help determine original cause of failure.
Page 346: Motor Frame And Field Windings Inspection
MOTOR (MODEL EJ4-4001) Motor Component Testing and Inspection MOTOR FRAME AND FIELD WINDINGS INSPECTION 1. Remove the motor from the vehicle. See Motor Removal, Section 22b, Page 22b-2. 2. Remove the and cap and armature by performing steps 1 through 7 of Motor Disassembly on page 22b-4.
Page 347 MOTOR (MODEL EJ4-4001) Motor Component Testing and Inspection Terminal Insulator Inspection 1. Remove the motor from the vehicle. See Motor Removal, Section 22b, Page 22b-2. 2. Remove the terminal insulators by performing steps 1 through 12 of Motor Disassembly on page 22b-4. 1.
Page 348 MOTOR (MODEL EJ4-4001) Motor Component Testing and Inspection TYPICAL 2 PLACES TYPICAL 4 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 3 PLACES Figure 22b-15 Motor – Model EJ4-4001 Page 22b-10 2005-2006 XRT 800, 800-E, 810, 810-E Maintenance and Service Manual...
Page 349: Reconditioning The Motor
MOTOR (MODEL EJ4-4001) Reconditioning the Motor RECONDITIONING THE MOTOR See General Warning, Section 1, Page 1-1. Motor reconditioning must be performed by a qualified motor repair technician. The use of proper tools and procedures is absolutely essential for successful motor reconditioning. Motor Specifications Any rework must be performed by a qualified technician.
Page 350 MOTOR (MODEL EJ4-4001) Motor Assembly Figure 22b-16 Brush Rigging Figure 22b-17 Retracted Brushes Figure 22b-18 Armature Installation Figure 22b-19 Brush Setting 2.5. One at a time, push the brushes back until they are completely retracted into their mounting slots and the spring pressure holds them in the retracted position as shown (Figure 22b-17, Page 22b-12).
Page 351: Motor Installation
MOTOR (MODEL EJ4-4001) Motor Installation MOTOR INSTALLATION See General Warning, Section 1, Page 1-1. 1. Clean the transaxle input shaft. ® 1.1. Spray the input shaft thoroughly with CRC Brakleen™ or equivalent brake cleaner degreaser. 1.2. Wipe input shaft with a clean cloth. 1.3.
Page 352 MOTOR (MODEL EJ4-4001) Motor Installation 4. Install motor on transaxle. 4.1. Slide the motor coupling onto the transaxle input shaft. See following NOTE. NOTE: The coupling will push any excess grease on the input shaft along the shaft toward the transaxle. When the motor is pushed onto the input shaft, the motor housing will not bottom out against the transaxle housing (Figure 22b-15, Page 22b-10).
Page 353 MOTOR (MODEL EJ4-4001) Motor Installation 6. Insert the mounting bolts through the spring shackles and the bushings in the leaf spring eyes and install locknuts. Tighten the bolts to 23 ft-lb (31 N·m). See Leaf Spring Installation, Section 9, Page 9-4. 7.
Page 355: Section 23 - Transaxle (Type G): Electric Vehicle
SECTION 23 – TRANSAXLE (TYPE G): ELECTRIC VEHICLE ý DANGER • See General Warning, Section 1, Page 1-1. ý WARNING • See General Warning, Section 1, Page 1-1. TRANSAXLE IDENTIFICATION This electric vehicle utilizes a different transaxle than does the gasoline vehicle. The different transaxles are identified by labels on the driver side axle tubes and are not interchangeable.
Page 356 TRANSAXLE (TYPE G): ELECTRIC VEHICLE Axle Bearing and Shaft Axle Shaft and Oil Seal Removal, Continued: 3. Use 90° internal snap ring pliers to remove the internal retaining ring (6) from the axle tube. (Figure 23-1, Page 23-2). 4. Remove the axle, retaining ring, and bearing assembly by pulling the axle straight out of the housing. 5.
Page 357 TRANSAXLE (TYPE G): ELECTRIC VEHICLE Axle Bearing and Shaft Figure 23-5 Axles And Tubes Axle Shaft and Oil Seal Installation 1. If previously removed, install a new oil seal. 1.1. Clean seal seat in the adapter ring (39) (Figure 23-3, Page 23-2). 1.2.
Page 358: Axle Bearing
TRANSAXLE (TYPE G): ELECTRIC VEHICLE Transaxle Axle Shaft and Oil Seal Installation, Continued: 2. Clean the shaft splines and then insert the shaft, splined end first, through the seal and into the axle tube. Be careful not to damage the seal. Then advance the shaft through the inner bearing and rotate it to align the shaft splines with the splined bore of the differential side gear.
Page 359 TRANSAXLE (TYPE G): ELECTRIC VEHICLE Transaxle 4. Remove the bow-tie pins (1), brake cable clevis pins (2), and cable retaining E-clips (3). Disconnect the brake cables (4) (Figure 23-7, Page 23-5). Figure 23-6 Vehicle Supported on Jack Stands Figure 23-7 Disconnect Brakes 5.
Page 360: Intermediate Gear Assembly
TRANSAXLE (TYPE G): ELECTRIC VEHICLE Transaxle Transaxle Removal, Continued: ý CAUTION • Do not position fingers under motor when sliding motor off of the input shaft. Fingers may get pinched when motor disengages. MOTOR MOUNTING BOLTS INPUT PINION GEAR INTERMEDIATE DIFFERENTIAL GEAR ASSEMBLY GEAR CASE...
Page 361: Transaxle Disassembly, Inspection, And Assembly
TRANSAXLE (TYPE G): ELECTRIC VEHICLE Transaxle Disassembly, Inspection, and Assembly TRANSAXLE DISASSEMBLY, INSPECTION, AND ASSEMBLY See General Warning, Section 1, Page 1-1. TRANSAXLE DISASSEMBLY AND INSPECTION 1. To detach axle tubes (14 and 35) from the transaxle housing, remove the bolts and lock washers (8 and 9) (Figure 23-14, Page 23-8).
Page 362 TRANSAXLE (TYPE G): ELECTRIC VEHICLE Transaxle Disassembly, Inspection, and Assembly Figure 23-14 Transaxle – Type G Page 23-8 2005-2006 XRT 800, 800-E, 810, 810-E Maintenance and Service Manual...
Page 363 TRANSAXLE (TYPE G): ELECTRIC VEHICLE Transaxle Disassembly, Inspection, and Assembly 8. Disassemble the differential gear case: 8.1. Remove four hex bolts (33) that secure the ring gear (32) to the differential case (26) (Figure 23-14, Page 23-8). 8.2. Remove the ring gear. Retain dowel pin (34) from between the ring gear and differential case for reassembly.
Page 364: Transaxle Assembly
TRANSAXLE (TYPE G): ELECTRIC VEHICLE Transaxle Disassembly, Inspection, and Assembly CAUT ION • Do not reuse bearings after removing them. Replace bearings with new ones. 9. Inspect parts for wear or damage. Any worn or damaged parts should be replaced. See following NOTE. NOTE: Damaged or worn gears should be replaced as sets.
Page 365: Transaxle Installation
TRANSAXLE (TYPE G): ELECTRIC VEHICLE Transaxle Installation 12. Install the retaining ring (6) in the axle tube. See following WARNING. ý WARNING • Be sure the retaining ring is properly seated in its groove. If the ring is not properly installed, the axle assembly will separate from the transaxle and damage the axle assembly and other components.
Page 367 INDEX testing ..............20-7 discharge test ..........20-9 accelerator interpreting test results ......20-10 cable hydrometer test ...........20-7 installation ...........14-9 removal ............14-9 interpreting results ........20-8 pedal (gas, V-Glide) on-charge voltage test .........20-7 installation .............5-7 voltage test ..........18-10 removal ............5-5 voltage test (under load) ......18-16 pedal (MCOR) troubleshooting examples ......20-11 installation ...........5-10...
Page 368 INDEX pedal connector, 16-pin free play adjustment see test procedures crankcase cover electric (MCOR) ........5-17 gasoline vehicle ........5-12 installation ............13-5 height adjustment removal ............13-3 electric (MCOR) ........5-16 cylinder head ............13-3 gasoline vehicle ........5-11 installation .............
Page 369 INDEX testing circuits ..........18-10 storage ............14-22 engine fuse assembly ............13-9 testing ............11-11 fuse, sense lead ..........18-29 removal ............13-3 rotation .............13-1 RPM adjustment ..........14-11 exhaust system ...........14-1 generator circuit see also muffler troubleshooting ..........11-20 governor governor system ..........16-1 governor cable floor mat installation and adjustment ......14-9 installation ............4-14 removal ............14-8...
Page 370 INDEX intake duct component installation ............14-13 inspection ..........22a-6 disassembly ........22a-4, 22b-4 removal ............14-13 features ............18-1 field winding inspection .......22a-6, 22b-8 identification ........22a-1, 22b-1 key switch installation ........22a-12, 22b-13 engine kill circuit testing ......... 11-28 motor braking ........... 18-1 installation ........12-14, 12-16, 19-2 protection circuit ..........
Page 371 INDEX installation ............5-4 gap adjustment ........13-2, 14-1 removal ..............5-3 installation ............13-2 pedal group adjustment removal ............13-1 electric (MCOR) ..........5-16 testing ..............13-2 gasoline vehicle ..........5-11 specifications torque .............13-10 rack and pinion vehicle ..............2-1 assembly ............7-10 speed controller disassembly ............7-7 connector, 16-pin installation ............7-12 see test procedures removal ..............7-7...
Page 372 INDEX components engine kill circuit ..........11-29 delta a-plate fuel gauge ............11-33 installation ..........7-19 fuel level sending unit ........11-32 removal ........... 7-16 fuse ..............11-11 kingpin and steering spindle ground cables ..........11-12 installation ..........7-16 headlight ............11-36 removal ...........
Page 373 INDEX transaxle, type g assembly ............23-10 axle bearing .............23-4 axle shaft installation ...........23-3 removal ............23-1 disassembly .............23-7 identification .............23-1 inspection ............23-7 installation ............23-11 lubrication ............23-1 oil seal installation ...........23-3 removal ............23-1 removal ............23-4 troubleshooting ..........18-2 see also testing battery troubleshooting examples ....20-11 communication display module (CDM) ..18-37 torque converter ..........17-1 troubleshooting guide 1 ........18-5...
Page 376 Golf Cars and Utility Vehicles Club Car Inc. P.O. Box 204658 Augusta, GA 30917-4658...

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